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Enabling reliable integration of rigid electronics onto flexible, body-worn sensors.

Proposed Uses

This invention provides a platform for manufacturing stretchable electronic devices suitable for continuous body-worn monitoring in healthcare and sports performance applications. Demonstrated applications include wearable respiratory monitors, lower-limb rehabilitation trackers, and hand-held devices for motor rehabilitation. The technology is also applicable to veterinary monitoring and to any product category requiring flexible, skin-conforming electronics with conventional circuit integration.

Problem addressed

A fundamental barrier to commercialising wearable and stretchable electronics is the unreliable connection between soft, flexible sensor elements and conventional rigid electronic components. Current approaches using conductive adhesives and epoxy glues are brittle and fail under real-world mechanical strain, limiting device longevity and preventing mass-market adoption of stretchable sensing platforms..

Technology Overview

This invention introduces a method to permanently attach standard electronic components — such as wires, microcontrollers, and sensors — to flexible silicone-based substrates through conventional soldering. A specialised contact interface is formed on the sensor surface, enabling reliable high-strength bonding that remains intact under repeated mechanical deformation. The process is compatible with existing mass-scale electronics manufacturing, supporting straightforward scale-up for commercial production.

Benefits

• First method enabling standard soldering on stretchable silicone substrates
• Highly durable connections that withstand real-world mechanical strain
• Compatible with existing mass-scale electronics manufacturing processes
• Platform technology applicable to any silicone-based sensor design