Development of a Wearable Electromyographic Sensor with Aerosol Jet Printing Technology

Electromyographic (EMG) sensors are essential tools for analyzing muscle activity, but traditional designs often face challenges such as motion artifacts, signal variability, and limited wearability. This study introduces a novel EMG sensor fabricated using Aerosol Jet Printing (AJP) technology that addresses these limitations with a focus on precision, flexibility, and stability. The innovative sensor design minimizes air interposition at the skin–electrode interface, thereby reducing variability and improving signal quality. AJP enables the precise deposition of conductive materials onto flexible substrates, achieving a thinner and more conformable sensor that enhances user comfort and wearability. Performance testing compared the novel sensor to commercially available alternatives, highlighting its superior impedance stability across frequencies, even under mechanical stress. Physiological validation on a human participant confirmed the sensor’s ability to accurately capture muscle activity during rest and voluntary contractions, with clear differentiation between low and high activity states. The findings highlight the sensor’s potential for diverse applications, such as clinical diagnostics, rehabilitation, and sports performance monitoring. This work establishes AJP technology as a novel approach for designing wearable EMG sensors, providing a pathway for further advancements in miniaturization, strain-insensitive designs, and real-world deployment. Future research will explore optimization for broader applications and larger populations.