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A Cost-Effective 3D-Printed Conductive Phantom for EEG Sensing System Validation: Development, Performance

Peter Akor1, Godwin Enemali1, Usman Muhammad1

  • 1School of Science and Engineering, Glasgow Caledonian University, Glasgow G4 0BA, UK.

Sensors (Basel, Switzerland)
|August 28, 2025
PubMed
Summary

A novel 3D-printed conductive phantom for electroencephalography (EEG) system validation offers an 85% cost reduction and rapid fabrication. This accessible technology provides consistent electrical properties for standardized electrode testing and broader research use.

Keywords:
3D printingadditive manufacturingconductive materialselectrode testingelectroencephalographyneuromonitoring sensorsneurophysiological signal acquisitionphantom headsensing system validationstandardized testing

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Area of Science:

  • Biomedical Engineering
  • Electrical Engineering
  • Materials Science

Background:

  • Current electroencephalography (EEG) phantom technologies face significant cost barriers (tooling £5000-£20,000) and lengthy fabrication times, limiting widespread adoption for system validation.
  • Existing phantoms include commercial injection-molded models, saline solutions, hydrogels, silicones, textiles, and multi-material systems, each with limitations in accessibility and standardization.

Purpose of the Study:

  • To develop and validate a cost-effective, 3D-printed conductive phantom for electroencephalography (EEG) sensing system validation.
  • To significantly reduce the cost and fabrication time of EEG phantoms while ensuring suitable electrical properties for standardized electrode testing.

Main Methods:

  • Fabrication of a two-component phantom using conductive PLA filament (conductive top, non-conductive base).
  • Validation through DC resistance measurements (821-1502 Ω), complex impedance spectroscopy (3.01-6.4 kΩ at 100 Hz), and 8-channel EEG system testing (5-11 kΩ impedance range).
  • Comparative analysis of the developed phantom against six existing phantom technologies.

Main Results:

  • Achieved an 85% cost reduction (£48.10 vs. £300-£500) and a 48-hour fabrication time.
  • Electrical characterization revealed spatial heterogeneity but consistent properties suitable for comparative electrode evaluation.
  • Demonstrated compatibility with clinical EEG acquisition systems for electrode performance and multi-channel system validation.

Conclusions:

  • The 3D-printed conductive phantom effectively addresses cost and accessibility barriers in current EEG validation technologies.
  • The phantom provides consistent and appropriate electrical properties for standardized EEG electrode testing and system validation.
  • This development democratizes access to EEG sensing system validation, fostering broader research and development in the field.