Lithographed Neural Electrode Cantilevers for Partial-Cut Release

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Solution Overview

Problem

Existing methods for implanting neural electrodes into biological tissue, such as the brain, do not effectively facilitate the removal of the electrodes from the substrate prior to piercing the tissue.

Innovation Solution

A method for fabricating a cantilever section in a structure by providing a substrate with a compliant layer and an optional sacrificial layer, cutting part-way through the substrate to create a linear partial cut, undercutting or releasing the sacrificial layer, and breaking the substrate along the cut to generate a cantilever section, which can be used to facilitate the removal of neural electrodes.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If neural electrodes are permanently attached to the substrate, then manufacturing and handling is simplified, but removal from the substrate prior to tissue piercing becomes difficult and may cause damage or contamination

Engineering Contradiction:

Improveease of handling during manufacturingVSAvoidease of removal prior to implantation

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The substrate is segmented into separate sections through partial cutting, creating defined separation zones that allow the electrode array to be divided into individual implantable units. This segmentation enables the electrodes to remain attached to the substrate during manufacturing while facilitating clean separation and removal when needed for implantation.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Partial cuts are made in the substrate in advance during manufacturing, creating pre-defined separation lines. These preliminary actions prepare the substrate for future removal operations, ensuring that when the electrodes need to be detached prior to implantation, the separation will occur cleanly along the pre-established cut lines without causing damage or contamination.

Inventive Principle:

Principle #10Preliminary action

2Ease of operation

If the substrate is completely cut to separate electrodes, then removal is facilitated, but structural integrity and alignment are compromised

Engineering Contradiction:

Improveease of removal from substrateVSAvoidalignment and structural integrity

Core Design Contradiction:

Ease of operationVSManufacturing precision

Solution Approach 1:

Instead of completing the cut through the entire substrate thickness, only partial cuts are made, extending partway through the substrate but stopping before complete separation. This partial action provides sufficient separation to facilitate removal while maintaining enough structural connection to preserve alignment and integrity during the removal process and subsequent implantation.

Inventive Principle:

Principle #16Partial or excessive action

Data Source

PatentUS12391032B2Dicing and partial dicing release of lithographed device

Publication Date: 2025.08.19 NEURALINK CORP

AI summary

The disclosure provides a method for fabricating a cantilever section in a structure, which includes providing a structure comprising a substrate, a compliant layer and a sacrificial layer therebetween; cutting part-way through the substrate to create an at least one linear partial cut; releasing the sacrificial layer from the structure; and breaking the substrate along the at least one linear partial cut to generate a cantilever section in a substrate.