Prototype flexible microneedle electrodes for long-term ECG monitoring

Developing electrodes that allow for long-term comfortable wear
Microneedle electrode

Prototype flexible microneedle electrodes for long-term ECG monitoring

Developing electrodes that allow for long-term comfortable wear
Title: Prototype flexible microneedle electrodes for long-term electrocardiogram (ECG) monitoring
Funding amount: £99,992
Location: UK
Dates: April–November 2026
University of Plymouth PI: Dr Om Prakash Singh
University of Plymouth project team: Dr Alexander Besinis, Dr David Jenkins
 

Overview

This project will develop and test a flexible microneedle (MN) electrode for comfortable, long-term ECG monitoring. 
The electrode combines a biocompatible solid polymer microneedle structure with a flexible substrate and a thin conductive metal coating. The flexible microneedle electrodes will be developed using 3D printing technology and micromoulding replication. 
By conforming to moving, uneven skin while maintaining a low-impedance interface, the technology aims to deliver stable, high-quality ECG signals without the drying gel used in conventional electrodes.

Clearer heart signals. Greater comfort. Longer wear. We are developing a next-generation ECG electrode that moves naturally with the body, helping people monitor their heart comfortably for longer. This early research is the first step towards bringing the technology out of the laboratory and into people’s lives.

Om Prakash SinghDr Om Prakash Singh
Lecturer in Digital Health

Objectives

1. Fabricate flexible MN electrodes with needle heights ranging from 300–500 µm using 3D printing technology and micromoulding replication, and optimise metal-coating thickness.
2. Develop skin-mimicking phantoms with controlled mechanical, electrical and hydration properties.
3. Characterise surface morphology, insertion force, compression, integrity and skin–electrode impedance.
4. Compare ECG signal fidelity with clinical wet-gel electrodes during bending, stretching and simulated motion.
Electron microscope image of a microneedle
Electron microscope image of a microneedle
Scanning electron microscope images of the microneedle

Context of the issue

Continuous ECG monitoring is increasingly important for detecting and managing cardiovascular disease in hospitals, clinics and home-care settings. Conventional wet-gel electrodes work well in the short term, but the gel can dry out, increasing skin–electrode impedance and reducing signal quality; prolonged use can also require skin preparation and cause irritation. 
The NHS uses more than 152 million wet-gel ECG electrodes annually. Flat dry electrodes avoid gel but may lose consistent contact with the uneven surface of the skin. Rigid microneedle electrodes can reduce impedance, yet their mechanical mismatch with soft, moving skin may cause discomfort, local pressure, delamination or damage.
Wet-gel electrode diagram
Microneedle electrodes

How the project addresses the issue

The research combines solid, biocompatible microneedles with a mechanically flexible substrate and conductive coating. The flexible microneedle electrodes will be produced using 3D printing technology and micromoulding replication, with designs spanning 300–500 µm needle heights. Two work packages will first optimise fabrication and evaluate the electrodes using a dry-testing skin phantom, then use a hydration-controlled, two-layer phantom to assess impedance and ECG signal fidelity under realistic motion. 
Scanning electron microscopy, mechanical testing and electrical measurements will establish tip integrity, insertion performance, durability and motion stability. The resulting pilot data will de-risk materials selection and device performance, support regulatory planning, and prepare the technology for human feasibility studies and integration with wearable ECG systems.

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