Implanting mechanics of PEG/DEX coated flexible neural probe: impacts of fabricating methods

Resorbable coatings are processed on flexible implants to facilitate penetrations. However, impacts of fabricating methods on implantation damage of coated probes are unclear. Herein, photosensitive polyimide (PSPI) based flexible neural implants are fabricated through clean-room technology. Polyethyleneglycol (PEG) - dexamethasone (DEX) coatings are processed through an improved micro moulding protocol in micro channels, fabricated by computer-numerical-controlled (CNC) micro milling, laser machining, and deep reactive ion etching (DRIE), respectively. An in vitro testing system is developed, using maximum insertion force [Formula: see text] and mean region-of-interest strain [Formula: see text] to accurately evaluate effects of the three fabricating methods on implantation damage at different insertion speed. Rat cerebrum, agarose gel, and silicone rubber are used as brain phantoms for tests. Results show that lower insertion speed, and micro channels fabricated by CNC micro milling or DRIE can minimize implantation damage. The decrease of insertion speed from 2.0 mm/s to 0.5 mm/s reduces [Formula: see text] by 76.2% ~85.1% and [Formula: see text] by 11.6% ~14.7%, respectively. Compared with laser machining, CNC micro milling and DRIE ensure dimensional accuracy of the PEG/DEX coating, reducing [Formula: see text] by 20.2% ~51.4% and [Formula: see text] by 8.0% ~11.6%, respectively. Compared with biological rat cerebrum, [Formula: see text] reduces by 5.8% ~25.1% in agarose gel phantom and increases by 7.7% ~21.0% in silicone rubber phantom, respectively. This study improves processing methods of polymer coatings and reveals mechanical difference between current used abiotic brain phantoms and biological brain tissues. Implantation tests establish quantitative relationship among insertion speed, fabricating methods, and implantation damage.