Optimization of Pressing Parameters for 3D Perfluoroalkoxy (PFA) Electrode Fabrication

Implantable device systems play a critical role in modern medicine, serving both as therapeutic tools for various diseases and as an essential means of interpreting biological phenomena. However, implanted electrodes frequently induce immune responses or cause persistent damage to the surrounding tissues owing their mechanical properties and biocompatibility. Additionally, unlike controlled in vitro environments, the stimulation efficiency often decreases in vivo due to the irregular surface of target tissues. In this study, we optimized the shape of a substrate and the pressing conditions for the fabrication of the plateau shaped electrodes based on perfluoroalkoxy alkane (PFA) film to enhance contact efficiency and biocompatibility. By optimizing the electrode structure, we aimed to enhance the performance in irregular biological environments while mitigating immune reactions and minimizing tissue damage.Clinical relevanceThe clinical relevance of this study lies in its potential for improving the long-term performance, safety, and stimulation efficiency of implantable electrodes. Minimizing cavity formation and its associated complications -such as bacterial growth, inflammation, increased impedance, and current leakage- three-dimensional (3D) electrodes can enhance the reliability of bioelectronic devices. Additionally, the improved contact between the electrode and tissue allows for more efficient current delivery, reduced power requirements and improved stimulation precision. This advancement could lead to more effective therapeutic outcomes in patients who require neural interfaces or other implants.