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Professional Engineering
A new type of microelectrode array for brain-computer interface platforms could “transform” how doctors treat neurological disorders, its creators have claimed.
Developed at Carnegie Mellon University in Pennsylvania, the ultra-high-density microelectrode array (MEA) is 3D-printed and fully customisable, according to the researchers.
“This means that one day, patients suffering from epilepsy or limb function loss due to stroke could have personalised medical treatment optimised for their individual needs,” a research announcement said.
The team used aerosol jet 3D printing to produce the arrays, which they say solve the major design barriers of other brain computer interface (BCI) arrays.
“Aerosol jet 3D printing offered three major advantages,” said Rahul Panat, associate professor of mechanical engineering. “Users are able to customise their MEAs to fit particular needs, the MEAs can work in three dimensions in the brain, and the density of the MEA is increased and therefore more robust.” 
MEA-based interfaces connect neurons in the brain with external electronics to monitor or stimulate brain activity. They are often used in applications such as neuroprosthetic devices and artificial limbs, transporting information from the brain to extremities. BCIs also have potential applications in treating neurological diseases such as epilepsy, depression, and obsessive compulsive disorder.
Existing devices have limitations, the researchers said – some previous types of popular BCI devices are unable to record in three-dimensions, so they cannot be customised to fit the needs of each patient or application.
The MEA, however, offers three-dimensional sampling, limited by the density of microelectrodes in the array and the ability to position these arrays in the precise position where they are needed.
Modern manufacturing techniques have made “tremendous” advances regarding the density of the microelectrode arrays, the researchers said. Custom-made MEAs for each specific application also allows for more accurate and higher-fidelity readings.
“MEAs used for controlling virtual actions on a computer or complex limb movements are running up on limitations of the current technology,” the researchers said. “More advanced applications require MEAs that are customised to each individual and are much higher fidelity than what is currently available.” 
Co-senior author Eric Yttri said: “Within a matter of days, we can now produce a precision medicine device tailored to a patient or experimenter’s needs.”
Being able to personalise the control system in the brain could pave the way for enormous advances in the field, the team predicted, but human testing might not be possible for five years. Commercial use will take even longer.
A patent on the CMU array architecture and manufacturing method is pending.
The team now aims to work with the National Institutes of Health and business partners to share findings with other labs, and to apply for funding to commercialise the technology.
The findings were published in Science Advances. 
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