A study on the fabrication of metal microneedle array electrodes for ECG detection based on low melting point Bi-In-Sn alloys

This study describes the fabrication and characteristics of microneedle array electrodes (MAEs) using Bismuth-Indium-Tin (Bi-In-Sn) alloys. The MAEs consist of 57 pyramid-shaped needles measuring 340 mu m wide and 800 mu m high. The fabrication process involved micromolding the alloys in a vacuum environment. Physical tests demonstrated that Bi-In-Sn MAEs have good mechanical strength, indicating their suitability for successful skin penetration. The electrode-skin interface impedance test confirmed that Bi-In-Sn MAEs successfully penetrated the skin. Impedance measurements revealed the importance of insulating the microneedle electrodes for optimal electrical performance, and a UV-curable Polyurethane Acrylate coating was applied to enhance insulation. Electrocardiogram measurements using the Bi-In-Sn MAEs demonstrated performance comparable to that of traditional Ag/AgCl electrodes, which shows promise for accurate data collection. Overall, the study demonstrates successful, minimally-invasive skin insertion, improved electrical insulation, and potential applications of Bi-In-Sn microneedle array. These findings contribute to advancements in microneedle technology for biomedical applications.