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Ion-shielding ultrathin encapsulation with hot-press bonded interface enables chronic stretchable bioelectronics
Zhi Jiang1,2, Guijin Zou3, Wei Ju4
1Innovative Center for Flexible Devices (iFLEX), Max Planck-NTU Joint Laboratory for Artificial Senses, School of Materials Science and Engineering, Nanyang Technological University, Singapore, Singapore.
Science Advances
|May 29, 2026
Summary
This study presents a novel ion-shielding encapsulation for stretchable electrodes, preventing water and ion damage. This breakthrough ensures stable, high-fidelity bio-signal monitoring for extended periods, crucial for advanced physiological tracking.
Area of Science:
- Biomedical Engineering
- Materials Science
- Neuroscience
Background:
- Stretchable physiological electrodes are vital for continuous bio-signal monitoring.
- Interfacial defects in electrodes allow water and ion ingress, leading to signal failure within weeks.
Purpose of the Study:
- To develop an advanced encapsulation method for stretchable electrodes to prevent aqueous ingress.
- To enhance the long-term stability and reliability of bio-signal monitoring devices.
Main Methods:
- Introduction of an ion-shielding ultrathin encapsulation molecularly fused to stretchable conductors.
- Utilizing a single-step hot-press bonding technique to create a defect-free interface.
- Testing the water and ion penetration resistance of the hot-press bonded interface.
Main Results:
- The hot-press bonded interface demonstrated resistance to water and ion penetration for over 12 months, exceeding untreated interfaces by more than 10 times.
- Stretchable electrodes with ~10-micrometer-thick encapsulation maintained stable, high-fidelity electrophysiological recordings.
- Continuous monitoring of cardiomyocytes for 29 days in vitro and rat spinal cords for 12 weeks in vivo confirmed device efficacy.
Conclusions:
- The developed ion-shielding encapsulation significantly improves the durability and longevity of stretchable physiological electrodes.
- This technology enables reliable, long-term bio-signal monitoring in challenging environments.
- The findings pave the way for next-generation wearable and implantable bioelectronic devices.
