To begin, use tape to secure the silicone base on the cutting jig. Perforate the silicone with cutting jig guides and an X-ACTO knife replacement of the contact foils. Using the folding jig, bend the biocompatible precut platinum or radium contact foils into a U-shape.
Insert the foils into the perforated slots in the silicone base to construct the contact surfaces of the electrode, ensuring proper spacing between electrodes. Place a piece of surgical tape over the contact surfaces to hold the foils in place. Remove the silicone base from the cutting jig.
Flip the silicone base to expose U-shaped foil arms. Hold one arm of each U-shaped foil flush with the silicone base. Cut the perfluoroalkoxy-coated stainless steel wire to a desired length.
Using a lighter, denude one end of the wire. Position the denuded end of the wire on the inside of the unfolded arm of the foil and weld it using a micro TIG welder. To test the wire foil connection, apply tension to the stainless steel wire.
If the connection holds, fold the foil arm down flush with the silicone base, and remove the tape bordering of the silicone sheet. Next, mix biocompatible liquid silicone with toluene until desired thinner or syrup-like consistency is achieved. Drop the mixture using an 18 gauge blunt tipped syringe and apply it to the back of the welded electrodes to seal it.
After 72 hours, use scissors to cut the silicone base into individual electrodes.
