Integrating coupled magnetoelastic sensors onto a flexible hernia mesh for high dynamic range strain measurements

Despite better performance over primary repairs, tension-free ventral hernia repairs with mesh still suffer from a high recurrence rate. High stress gradients in the mesh are thought to contribute to hernia recurrence. We propose a postoperative monitoring system based on a coupled pair of magnetoelastic strain sensors to enable patients and physicians to non-invasively measure and track the strain distribution across the hernia mesh. Our design combines an encased resonator with a spring-loaded transducer to achieve high signal amplitude with a wide dynamic range. We also demonstrate a fabrication protocol to integrate the resonant strain sensors with a commercial polypropylene mesh. The packaged sensor is capable of detecting up to 37.5 millistrain, an order of magnitude greater than previously demonstrated.