Ultra-small carbon fiber electrode recording site optimization and improved in vivo chronic recording yield

Objective.Carbon fiber electrodes may enable better long-term brain implants, minimizing the tissue response commonly seen with silicon-based electrodes. The small fiber diameter may enable high-channel count brain-machine interfaces capable of reproducing dexterous movements. Past carbon fiber electrodes exhibited both high fidelity single unit recordings and a healthy neuronal population immediately adjacent to the recording site. However, the recording yield of our carbon fiber arrays chronically implanted in the brain typically hovered around 30%, for previously unknown reasons. In this paper we investigated fabrication process modifications aimed at increasing recording yield and longevity.Approach.We tested a new cutting method using a 532nm laser against traditional scissor methods for the creation of the electrode recording site. We verified the efficacy of improved recording sites with impedance measurements andin vivoarray recording yield. Additionally, we tested potentially longer-lasting coating alternatives to PEDOT:pTS, including PtIr and oxygen plasma etching. New designs were evaluated with accelerated soak testing and acute recording.Main results.We found that the laser created a consistent, sustainable 257 ± 13.8μm2electrode with low 1kHz impedance (19 ± 4kΩ with PEDOT:pTS) and low fiber-to-fiber variability. The PEDOT:pTS coated laser-cut fibers were found to have high recording yield in acute (97% >100μVpp, N=34 fibers) and chronic (84% >100μVpp, day 7; 71% >100μVpp, day 63, N=45 fibers) settings. The laser-cut recording sites were good platforms for the PtIr coating and oxygen plasma etching, slowing the increase in 1kHz impedance compared to PEDOT:pTS in an accelerated soak test.Significance.We have found that laser-cut carbon fibers have a high recording yield that can be maintained for over two monthsin vivoand that alternative coatings perform better than PEDOT:pTS in accelerated aging tests. This work provides evidence to support carbon fiber arrays as a viable approach to high-density, clinically-feasible brain-machine interfaces.

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