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Integrated hierarchical surface restructuring of assembled electrode arrays for next-generation neural interfaces
Alexander Blagojevic1, Wesley Roser1, Wesley Seche2
1Department of Biomedical Engineering, University of Connecticut, Storrs, Connecticut, United States of America.
Plos One
|June 2, 2026
Summary
Hierarchical Surface Restructuring (HSR™) laser technology enhances neurostimulation electrodes by increasing surface area for better performance. This study shows HSR™ can be a cost-effective, post-fabrication step for medical device manufacturing.
Area of Science:
- Biomedical Engineering
- Materials Science
Background:
- Neurostimulation devices require advanced electrodes for improved nerve modulation.
- Current electrodes face limitations in specificity, energy efficiency, and miniaturization.
- Hierarchical Surface Restructuring (HSR™) offers potential for high-performance, low-profile electrodes.
Purpose of the Study:
- To investigate the feasibility of applying HSR™ to commercial Pt-10Ir paddle electrodes.
- To demonstrate HSR™ as a post-fabrication surface modification process compatible with existing manufacturing.
- To assess the manufacturing viability and cost-effectiveness of HSR™ for neurostimulation electrodes.
Main Methods:
- Application of femtosecond laser-based HSR™ to Pt-10Ir paddle electrodes.
- Characterization of electrode morphology, electrochemical performance, and processing efficiency.
- In-operando CO2-snow-assisted processing for enhanced stability and cleanliness.
Main Results:
- HSR™ significantly increased electrochemically active surface area, creating multi-scale architectures.
- Electrochemical metrics (charge storage capacity, specific capacitance, impedance) improved by up to two orders of magnitude.
- HSR™ demonstrated compatibility with existing device geometry, materials, and production workflows, with short processing times.
Conclusions:
- HSR™ can be seamlessly integrated as a post-fabrication step in medical device manufacturing.
- This approach overcomes cost and complexity barriers, enabling broader adoption of HSR™.
- HSR™ offers a scalable, cost-effective method to enhance neurostimulation electrode performance and manufacturing viability.
