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Lab to Fab Process Using Ablation Lasers: A Lightweight, Flexible, and Biocompatible Microheater for Wearable Therapy

Bhavani Prasad Yalagala1, Tahereh Masalehdan1, Changhao Ge1

  • 1Microelectronics Lab (meLAB), School of Engineering, University of Glasgow, Glasgow G12 8QQ, U.K.

ACS Applied Bio Materials
|October 17, 2025
PubMed
Summary

A novel ultraviolet laser ablation method fabricates precise, scalable flexible microheaters for advanced thermal therapy. This technique enables rapid prototyping of wearable devices for accelerated wound healing and other biomedical applications.

Keywords:
Parylene Cablation laserbiocompatibilityflexibilitygold electrodesmicroheaterswearables

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Area of Science:

  • Biomedical Engineering
  • Materials Science
  • Nanotechnology

Background:

  • Wearable thermal therapy, particularly for wound healing, is gaining traction.
  • Current fabrication methods for smart bandages face limitations in precision, scalability, and material compatibility.

Purpose of the Study:

  • To develop a scalable, high-precision fabrication method for flexible microheaters using ultraviolet (UV) laser ablation.
  • To design and fabricate diverse microheater arrays on biocompatible substrates for targeted thermal therapy applications.

Main Methods:

  • Utilized UV laser ablation for large-area, precision fabrication of microheaters on gold-coated polymer substrates.
  • Designed and fabricated various microheater designs (circular, hexagonal, planar) with sizes tailored for temperatures from 30 °C to 100 °C.
  • Conducted electrical, electrothermal, mechanical flexibility, and biocompatibility assessments.

Main Results:

  • Demonstrated a unique laser-based approach offering rapid prototyping, material versatility, and minimal thermal damage.
  • Fabricated thin, flexible, biocompatible microheaters with varying electrical and thermal characteristics based on design and size.
  • Confirmed excellent mechanical robustness and biocompatibility of the fabricated devices.

Conclusions:

  • The UV laser ablation method provides an effective pathway for next-generation wearable and implantable biointegrated flexible microheaters.
  • This technology holds significant potential for advanced thermal therapy solutions, especially in accelerated wound healing.
  • The developed microheaters are suitable for diverse biomedical applications requiring precise thermal control.