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Aerosol Jet Printing for Neuroprosthetic Device Development
Lander De Waele1, Massimo Di Pietro2,3, Stefano Perilli4
1Movement Control and Neuroplasticity Research Group, KU Leuven, Tervuursevest 101, 3001 Leuven, Belgium.
Bioengineering (Basel, Switzerland)
|July 29, 2025
Summary
Aerosol jet printing (AJP) offers precise fabrication for advanced neuroprosthetic devices. This technology enables the development of sophisticated neural interfaces and intelligent prostheses with enhanced functionality.
Area of Science:
- Biomedical Engineering
- Materials Science
- Neuroscience
Background:
- Aerosol jet printing (AJP) is a key technology for fabricating miniaturized and complex structures.
- Advanced neural interfaces require high accuracy and versatility in device manufacturing.
Purpose of the Study:
- To review the principles, advantages, and applications of AJP in neuroprosthetic device development.
- To highlight AJP's potential in creating next-generation neural interfaces and prosthetics.
Main Methods:
- Exploration of AJP's aerosol generation and deposition mechanisms.
- Examination of AJP's scalability, substrate compatibility, and material versatility.
- Discussion of key implementations in neural interfaces, microelectrode arrays, and flexible electronics.
Main Results:
- AJP facilitates the use of diverse biocompatible materials on various substrates, including flexible and stretchable ones.
- Successful fabrication of neural interfaces, microelectrode arrays, and integrated flexible electronics using AJP.
- Identification of challenges including biocompatibility and long-term stability of conductive traces.
Conclusions:
- AJP is a transformative technology for advancing neuroprosthetic applications.
- Future directions include sensorized prosthetic limbs, biosensor integration, and intelligent prostheses.
- AJP shows significant potential for clinical translation and commercialization in neuroprosthetics.

