Structured 3D Printed Dry ECG Electrodes Using Copper Based Filament

Commercial Silver and Silver Chloride (Ag/AgCl) wet electrodes are used to monitor electrocardiogram (ECG) signals in numerous bioimpedance applications. These electrodes are single-use components that irritate the skin during the replacement and removal of electrodes, making the process uncomfortable for the patient. This study introduces the use of a copper-based filament with the highest reported conductivity (0.006 ω.cm) in biomedical applications, showcasing the process parameters of 3D printed, semi-flexible and wearable dry electrodes to monitor ECG signals. The effect of the printing-process parameters on the electrical performance is thoroughly investigated (10 parameters and >100 electrode samples) to find the printed electrodes' highest conductivity and lowest impedance. The results showed the concentric and flat dry electrode structures of Tbed = 80 °C and Tnozzle = 140 and 150 °C with the best performance, confirming that different electrode structures and printing parameters significantly influence electrodes' functionality, conductivity, and impedance measurements.