Open-source Toolkit: Benchtop Carbon Fiber Microelectrode Array for Nerve Recording.

Area of Science:

• Biomedical Engineering
• Materials Science
• Neuroscience

Background:

• Conventional neural electrode fabrication relies on expensive, specialized cleanroom equipment.
• Existing carbon fiber arrays often lack individualized electrodes or require complex cleanroom guides.
• There is a need for accessible, cost-effective neural probe fabrication methods.

Purpose of the Study:

• To present a cleanroom-light fabrication process for carbon fiber neural electrode arrays.
• To demonstrate the efficacy of UV laser-cut fibers for in vivo neural recording.
• To offer a customizable and affordable alternative to commercial neural probes.

Main Methods:

• Developed a fabrication process using a single cleanroom tool (Parylene C deposition) and benchtop techniques.
• Explored three tip optimization methods: Nd:YAG laser, blowtorch, and UV laser.
• Hand-populated printed circuit boards and insulation, optimized electrode tips.

Main Results:

• The fabrication process is learnable by inexperienced users and can be outsourced.
• Blowtorched fibers exhibited the lowest 1 kHz impedance.
• UV laser-cut fibers successfully recorded neural signals in vivo.
• The proposed arrays allow for benchtop population and insulation.

Conclusions:

• The cleanroom-light fabrication method significantly reduces cost and complexity for creating carbon fiber neural electrode arrays.
• UV laser-cut carbon fiber electrodes are viable for in vivo neural recording.
• This approach enables rapid customization and bulk fabrication at a lower price point.