3D Printed Wearable Sensor with Elastomeric Mesh for Adhesive-Free Attachment
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Solution Overview
Problem
Current wearable sensing technologies face challenges in creating custom-made devices tailored to specific biomarkers or use cases due to complex development processes and long development times, often requiring adhesives that limit attachment duration and user interaction, such as battery recharging or wired hardware, which inhibits mobility and experimental paradigms.
Innovation Solution
Three-dimensionally printed, wearable, electronic sensing articles with a flexible elastomeric mesh structure that conforms to the body, powered by far-field energy harvesting and embedded sensors, allowing for continuous, adhesive-free attachment and high-fidelity biodata acquisition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesive is used to attach wearable sensing article to body, then attachment security is improved, but attachment duration is limited to less than one week at best two weeks
Solution Approach 1:
The patent removes the adhesive component entirely from the wearable sensing article system. The article is designed to be attached to the body without any adhesive, thereby eliminating the fundamental limitation that adhesive degradation imposes on attachment duration. This extraction of the adhesive element allows the sensing article to remain attached indefinitely as long as the mechanical fit remains adequate.
Solution Approach 2:
The sensing article incorporates an elastomeric base with a mesh structure that dynamically adapts to body movements and shape changes. This dynamic flexibility maintains intimate skin contact and secure attachment without relying on adhesive bonds, enabling long-term wear by continuously adjusting to physiological changes in the underlying body surface.
2Measurement precision
If custom-made devices are created to be tailored to specific biomarkers or use cases, then sensing fidelity is improved, but development time becomes prohibitively long
Solution Approach 1:
The patent utilizes 3D printing technology to rapidly manufacture custom-fitted sensing articles by digitally modifying geometric parameters of the base structure. Instead of lengthy custom development processes, the system allows for quick parameter adjustments in digital models that are then directly manufactured, reducing development time from weeks or months to days or hours while maintaining custom fit and sensing fidelity.
Solution Approach 2:
The system performs preliminary 3D scanning and digital modeling of the patient's body to create a customized template before manufacturing the sensing article. This preliminary digital preparation enables rapid customization without requiring time-consuming iterative fitting and adjustment processes, as the digital model can be quickly modified and printed to achieve the desired custom fit.
3Reliability
If wired hardware is used for data collection, then data acquisition reliability is improved, but user mobility is inhibited
Solution Approach 1:
The patent replaces wired mechanical connections with wireless communication technology. The sensing article incorporates wireless transmitters that send collected physiological data remotely to external devices, eliminating the need for physical wires or cables. This substitution maintains reliable data acquisition through wireless protocols while completely removing the mobility restrictions that wired hardware imposes on the user.
4Adaptability or versatility
If battery-powered electronics are used in wearable article, then sensing functionality is enabled, but user interaction for recharging is required
Solution Approach 1:
The sensing article incorporates energy harvesting capabilities that allow it to generate and store its own power autonomously through the wearer's natural movements or environmental energy sources. This self-service power generation eliminates the need for user intervention to recharge batteries, as the device automatically replenishes its own energy supply during normal wear, maintaining continuous sensing functionality without requiring user interaction for power management.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables continuous, clinical-grade data collection over extended periods with improved fidelity and reduced bulk, facilitating advanced diagnostics and patient monitoring without the limitations of traditional adhesives or battery recharging.
Implementation Method 1
The base may be formed of an elastomeric polymer composition, to provide a base which is flexible, soft and stretchable (elastic), whereby the base is conformable (e.g. circumferentially) to changes in body shape of the wearer's body during movement, particularly by elastic deformation.
Data Source
AI summary
Three-dimensionally (3D) printed, wearable, electronic sensing articles and methods of manufacture are disclosed.