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Medical electrophysiological sensors that can study the body and diagnosediseases depend on consistently low impedance electrode-skin interfaces.Clinical-standard wet electrodes use hydrogels and skin abrasion to improve theinterface and thus the recorded signal quality. These electrodes arechallenging to self-administer and impede in-home care. Wearable dry electrodesare more practical; however, they show higher impedances than wet electrodesand are costly to customize. This work presents a fabrication method forrapidly producing low impedance, anatomically fit dry electrodes that do notrequire hydrogels. By using electroless copper and gold plating with 3Dprinting, biocompatible electrodes can be optimized for individuals at afraction of the cost of existing vacuum deposition-based techniques. Example 3Ddry electrodes made with this process are evaluated alongside clinical-standarddevices in typical scenarios to compare electrical performance and comfort. Theresulting dry electrodes exhibited an average electrode-skin impedance of 66.7k{\Omega} at 50Hz and DC offset of -20 mV without any hydrogel, which, whenarea normalized, is within the range achieved by wet electrodes without skinabrasion.

Rapid Fabrication of Low Impedance, 3D Dry Electrodes for Physiological Sensing