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Method Article
Here, we describe fabrication methodology for customizable carbon fiber electrode arrays for recording in vivo in nerve and brain.
Conventional peripheral nerve probes are primarily fabricated in a cleanroom, requiring the use of multiple expensive and highly specialized tools. This paper presents a cleanroom "light" fabrication process of carbon fiber neural electrode arrays that can be learned quickly by an inexperienced cleanroom user. This carbon fiber electrode array fabrication process requires just one cleanroom tool, a Parylene C deposition machine, that can be learned quickly or outsourced to a commercial processing facility at marginal cost. This fabrication process also includes hand-populating printed circuit boards, insulation, and tip optimization.
The three different tip optimizations explored here (Nd:YAG laser, blowtorch, and UV laser) result in a range of tip geometries and 1 kHz impedances, with blowtorched fibers resulting in the lowest impedance. While previous experiments have proven laser and blowtorch electrode efficacy, this paper also shows that UV laser-cut fibers can record neural signals in vivo. Existing carbon fiber arrays either do not have individuated electrodes in favor of bundles or require cleanroom fabricated guides for population and insulation. The proposed arrays use only tools that can be used at a benchtop for fiber population. This carbon fiber electrode array fabrication process allows for quick customization of bulk array fabrication at a reduced price compared to commercially available probes.
Much of neuroscience research relies upon recording neural signals using electrophysiology (ePhys). These neural signals are crucial to understanding the functions of neural networks and novel medical treatments such as brain machine and peripheral nerve interfaces1,2,3,4,5,6. Research surrounding peripheral nerves requires custom-made or commercially available neural recording electrodes. Neural recording electrodes-unique tools with micron-scale dimensions and fragile materials-require a specialized set of skills and equipment to fabricate. A variety of specialized probes have been developed for specific end uses; however, this implies that experiments must be designed around currently available commercial probes, or a laboratory must invest in the development of a specialized probe, which is a lengthy process. Due to the wide variety of neural research in peripheral nerve, there is high demand for a versatile ePhys probe4,7,8. An ideal ePhys probe would feature a small recording site, low impedance9, and a financially realistic price point for implementation in a system3.
Current commercial electrodes tend to either be extraneural or cuff electrodes (Neural Cuff10, MicroProbes Nerve Cuff Electrode11), which sit outside the nerve, or intrafascicular, which penetrate the nerve and sit within the fascicle of interest. However, as cuff electrodes sit further away from the fibers, they pick up more noise from nearby muscles and other fascicles that may not be the target. These probes also tend to constrict the nerve, which can lead to biofouling-a build-up of glial cells and scar tissue-at the electrode interface while the tissue heals. Intrafascicular electrodes (such as LIFE12, TIME13, and Utah Arrays14) add the benefit of fascicle selectivity and have good signal-to-noise ratios, which is important in discriminating signals for machine interfacing. However, these probes do have issues with biocompatibility, with nerves becoming deformed over time3,15,16. When bought commercially, both these probes have static designs with no option for experiment-specific customization and are costly for newer laboratories.
In response to the high cost and biocompatibility issues presented by other probes, carbon fiber electrodes may offer an avenue for neuroscience laboratories to build their own probes without the need for specialized equipment. Carbon fibers are an alternative recording material with a small form factor that allows for low damage insertion. Carbon fibers provide better biocompatibility and considerably lower scar response than silicon17,18,19 without the intensive cleanroom processing5,13,14. Carbon fibers are flexible, durable, easily integrated with other biomaterials19, and can penetrate and record from nerve7,20. Despite the many advantages of carbon fibers, many laboratories find the manual fabrication of these arrays arduous. Some groups21 combine carbon fibers into bundles that collectively result in a larger (~200 µm) diameter; however, to our knowledge, these bundles have not been verified in nerve. Others have fabricated individuated carbon fiber electrode arrays, although their methods require cleanroom-fabricated carbon fiber guides22,23,24 and equipment to populate their arrays17,23,24. To address this, we propose a method of fabricating a carbon fiber array that can be performed at the laboratory benchtop that allows for impromptu modifications. The resulting array maintains individuated electrode tips without specialized fiber populating tools. Additionally, multiple geometries are presented to match the needs of the research experiment. Building from previous work8,17,22,25, this paper provides detailed methodologies to build and modify several styles of arrays manually with minimal cleanroom training time needed.
All animal procedures were approved by the University of Michigan Institutional Animal Care and Use Committee.
1. Choosing a carbon fiber array
2. Soldering the connector to the circuit board
3. Fiber population
4. Applying ultra-violet (UV) epoxy to insulate the carbon fibers
5. Checking electrical connections with 1 kHz impedance scans (Figure 5)
6. Parylene C Insulation
NOTE: Parylene C was chosen as the insulation material for the carbon fibers as it can be deposited at room temperature over batches of arrays and provides a highly conformal coating.
7. Tip preparation methods
NOTE: Two tip preparations in this section use lasers to cut fibers. Proper PPE, such as goggles resistant to the wavelengths used, should always be worn when using the laser, and other lab users in the vicinity of the laser should also be in PPE. Although fiber lengths listed in these steps are recommended lengths, users may try any length that suits their needs. The user must choose one of the following tip preparation methods as scissor cutting alone will not suffice to re-expose the electrode25.
8. Poly(3,4-ethylenedioxythiophene):p-toluenesulfonate (PEDOT:pTS) conductive coating for lowered impedance
9. Connecting ground and reference wires
10. Surgical procedure
NOTE: Rat cortex was used to test the efficacy of the UV Laser-prepared fibers as this has been described previously7,20. These probes will work in nerve due to their similar geometry and impedance levels to blowtorch prepared fibers. This surgery was performed with an abundance of caution to validate that the UV laser did not change the response of the electrodes.
11. Spike sorting
12. Scanning electron microscopic (SEM) imaging
NOTE: This step will render arrays unusable and should be used only to inspect tip treatment results to check that the arrays are being properly processed. This step does not need to be done to build a successful array. Summarized below is a general outline of the SEM process; however, users who have not previously used SEM should receive help from a trained user.
Tip validation: SEM images
Previous work20 showed that scissor cutting resulted in unreliable impedances as Parylene C folded across the recording site. Scissor cutting is used here only to cut fibers to the desired length before processing with an additional finish cutting method. SEM images of the tips were used to determine the exposed carbon length and tip geometry (Figure 8).
Scissor and Nd:YAG laser-cut fibers w...
Material substitutions
While all materials used are summarized in the Table of Materials, very few of the materials are required to come from specific vendors. The Flex Array board must come from the listed vendor as they are the only company that can print the flexible board. The Flex Array connector must also be ordered from the vendor listed as it is a proprietary connector. Parylene C is highly recommended as the insulation material for the fibers as it provides a conformal coa...
The authors declare that they have no competing financial interests.
This work was financially supported by the National Institutes of Neurological Disorders and Stroke (UF1NS107659 and UF1NS115817) and the National Science Foundation (1707316). The authors acknowledge financial support from the University of Michigan College of Engineering and technical support from the Michigan Center for Materials Characterization and the Van Vlack Undergraduate Laboratory. The authors thank Dr. Khalil Najafi for the use of his Nd:YAG laser and the Lurie Nanofabrication Facility for the use of their Parylene C deposition machine. We would also like to thank Specialty Coating Systems (Indianapolis, IN) for their help in the commercial coating comparison study.
Name | Company | Catalog Number | Comments |
3 prong clams | 05-769-6Q | Fisher | Qty: 2 Unit Cost (USD): 20 |
3,4-ethylenedioxythiophene (25 g) (PEDOT) | 96618 | Sigma-Aldrich | Qty: 1 Unit Cost (USD): 102 |
353ND-T Epoxy (8oz)++ (ZIF and Wide Board Only) | 353ND-T/8OZ | Epoxy Technology | Qty: 1 Unit Cost (USD): 48 |
Ag/AgCl (3M NaCl) Reference Electrode (pack of 3) | 50-854-570 | Fisher | Qty: 1 Unit Cost (USD): 100 |
Autolab | PGSTAT12 | Metrohm | |
Blowtorch | 1WG61 | Grainger | Qty: 1 Unit Cost (USD): 36 |
Carbon Fibers | T-650/35 3K | Cytec Thornel | Qty: 1 Unit Cost (USD): n/a |
Carbon tape | NC1784521 | Fisher | Qty: 1 Unit Cost (USD): 27 |
Cotton Tipped Applicator | WOD1002 | MediChoice | Qty: 1 Unit Cost (USD): 0.57 |
Delayed Set Epoxy++ | 1FBG8 | Grainger | Qty: 1 Unit Cost (USD): 3 |
DI Water | n/a | n/a | Qty: n/a Unit Cost (USD): n/a |
Dumont Tweezers #5 | 50-822-409 | Fisher | Qty: 1 Unit Cost (USD): 73 |
Flex Array** | n/a | MicroConnex | Qty: 1 Unit Cost (USD): 68 |
Flux | SMD291ST8CC | DigiKey | Qty: 1 Unit Cost (USD): 13 |
Glass Capillaries (pack of 350) | 50-821-986 | Fisher | Qty: 1 Unit Cost (USD): 60 |
Glass Dish | n/a | n/a | Qty: 1 Unit Cost (USD): n/a |
Hirose Connector (ZIF Only) | H3859CT-ND | DigiKey | Qty: 2 Unit Cost (USD): 2 |
Light-resistant Glass Bottle | n/a | Fisher | Qty: 1 Unit Cost (USD): n/a |
Micropipette Heating Filiment | FB315B | Sutter Instrument Co | Qty: 1 Unit Cost (USD): n/a |
Micropipette Puller | P-97 | Sutter Instrument Co | Qty: 1 Unit Cost (USD): n/a |
Nitrile Gloves (pack of 200) | 19-041-171C | Fisher | Qty: 1 Unit Cost (USD): 47 |
Offline Sorter software | n/a | Plexon | Qty: 1 Unit Cost (USD): n/a |
Omnetics Connector* (Flex Array Only) | A79025-001 | Omnetics Inc | Qty: 1 Unit Cost (USD): 35 |
Omnetics Connector* (Flex Array Only) | A79024-001 | Omnetics Inc | Qty: 1 Unit Cost (USD): 35 |
Omnetics to ZIF connector | ZCA-OMN16 | Tucker-Davis Technologies | Qty: 1 Unit Cost (USD): n/a |
Pin Terminal Connector (Wide Board Only) | ED11523-ND | DigiKey | Qty: 16 Unit Cost (USD): 10 |
Probe storage box | G2085 | Melmat | Qty: 1 Unit Cost (USD): 2 |
Razor Blade | 4A807 | Grainger | Qty: 1 Unit Cost (USD): 2 |
SEM post | 16327 | lnf | Qty: 1 Unit Cost (USD): 3 |
Silver Epoxy (1oz)++ | H20E/1OZ | Epoxy Technology | Qty: 1 Unit Cost (USD): 125 |
Silver GND REF wires | 50-822-122 | Fisher | Qty: 1 Unit Cost (USD): 423.2 |
Sodium p-toulenesulphonate(pTS)- 100g | 152536 | Sigma-Aldrich | Qty: 1 Unit Cost (USD): 59 |
Solder | 24-6337-9703 | DigiKey | Qty: 1 Unit Cost (USD): 60 |
Soldering Iron Tip | T0054449899N-ND | Digikey | Qty: 1 Unit Cost (USD): 13 |
Soldering Station | WD1002N-ND | Digikey | Qty: 1 Unit Cost (USD): 374 |
SpotCure-B UV LED Cure System | n/a | FusionNet LLC | Qty: 1 Unit Cost (USD): 895 |
Stainless steel rod | n/a | n/a | Qty: 1 Unit Cost (USD): n/a |
Stir Plate | n/a | Fisher | Qty: 1 Unit Cost (USD): n/a |
Surgical Scissors | 08-953-1B | Fisher | Qty: 1 Unit Cost (USD): 100 |
TDT Shroud (ZIF Only) | Z3_ZC16SHRD_RSN | TDT | Qty: 1 Unit Cost (USD): 3.5 |
Teflon Tweezers | 50-380-043 | Fisher | Qty: 1 Unit Cost (USD): 47 |
UV & Visible Light Safety Glassees | 92522 | Loctite | Qty: 1 Unit Cost (USD): 45 |
UV Epoxy (8oz)++ (Flex Array Only) | OG142-87/8OZ | Epoxy Technology | Qty: 1 Unit Cost (USD): 83 |
UV Laser | n/a | WER | Qty: 1 Unit Cost (USD): 30 |
Weigh boat (pack of 500) | 08-732-112 | Fisher | Qty: 1 Unit Cost (USD): 58 |
Wide Board+ | n/a | Advanced Circuits | Qty: 1 Unit Cost (USD): 3 |
ZIF Active Headstage | ZC16 | Tucker-Davis Technologies | Qty: 1 Unit Cost (USD): 925 |
ZIF Passive Headstage | ZC16-P | Tucker-Davis Technologies | Qty: 1 Unit Cost (USD): 625 |
ZIF* | n/a | Coast to Coast Circuits | Qty: 1 Unit Cost (USD): 9 |
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