Smart Brace for Static and Dynamic Knee Laxity Measurement.

Every year in Europe more than 500 thousand injuries that involve the anterior cruciate ligament (ACL) are diagnosed. The ACL is one of the main restraints within the human knee, focused on stabilizing the joint and controlling the relative movement between the tibia and femur under mechanical stress (i.e., laxity). Ligament laxity measurement is clinically valuable for diagnosing ACL injury and comparing possible outcomes of surgical procedures. In general, knee laxity assessment is manually performed and provides information to clinicians which is mainly subjective. Only recently quantitative assessment of knee laxity through instrumental approaches has been introduced and become a fundamental asset in clinical practice. However, the current solutions provide only partial information about either static or dynamic laxity. To support a multiparametric approach using a single device, an innovative smart knee brace for knee laxity evaluation was developed. Equipped with stretchable strain sensors and inertial measurement units (IMUs), the wearable system was designed to provide quantitative information concerning the drawer, Lachman, and pivot shift tests. We specifically characterized IMUs by using a reference sensor. Applying the Bland-Altman method, the limit of agreement was found to be less than 0.06 m/s2 for the accelerometer, 0.06 rad/s for the gyroscope and 0.08 µT for the magnetometer. By using an appropriate characterizing setup, the average gauge factor of the three strain sensors was 2.169. Finally, we realized a pilot study to compare the outcomes with a marker-based optoelectronic stereophotogrammetric system to verify the validity of the designed system. The preliminary findings for the capability of the system to discriminate possible ACL lesions are encouraging; in fact, the smart brace could be an effective support for an objective and quantitative diagnosis of ACL tear by supporting the simultaneous assessment of both rotational and translational laxity. To obtain reliable information about the real effectiveness of the system, further clinical validation is necessary.

Printed Smart Devices on Cellulose-Based Materials by means of Aerosol-Jet Printing and Photonic Curing.

Printed electronics is an expanding research field that can reach the goal of reducing the environmental impact on electronics exploiting renewable and biodegradable materials, like paper. In our work, we designed and tested a new method for fabricating hybrid smart devices on cellulose substrates by aerosol jet printing (AJP) and photonic curing, also known as flash lamp annealing (FLA), capable to cure low temperature materials without any damage. Three different cellulose-based materials (chromatographic paper, photopaper, cardboard) were tested. Multilayer capability and SMDs (surface mount devices) interconnections are possible permitting high flexibility in the fabrication process. Electrical and geometrical tests were performed to analyze the behavior of printed samples. Resulted resistivities are 26.3 × 10-8 m on chromatographic paper, 22.3 × 10-8 m on photopaper and 13.1 × 10-8 m on cardboard. Profilometer and optical microscope evaluations were performed to state deposition quality and penetration of the ink in cellulose materials (thicknesses equal to 24.9, 28.5, and 51 µm respectively for chromatographic paper, photopaper, and cardboard). Furthermore, bending (only chromatographic paper did not reach the break-up) and damp environment tests (no significant variations in resistance) where performed. A final prototype of a complete functioning multilayer smart devices on cellulose 3D-substrate is shown, characterized by multilayers, capacitive sensors, SMDs interconnections.

Printed Strain Gauge on 3D and Low-Melting Point Plastic Surface by Aerosol Jet Printing and Photonic Curing.

Printing sensors and electronics directly on the objects is very attractive for producing smart devices, but it is still a challenge. Indeed, in some applications, the substrate that supports the printed electronics could be non-planar or the thermal curing of the functional inks could damage temperature-sensitive substrates such as plastics, fabric or paper. In this paper, we propose a new method for manufacturing silver-based strain sensors with arbitrary and custom geometries directly on plastic objects with curvilinear surfaces: (1) the silver lines are deposited by aerosol jet printing, which can print on non-planar or 3D surfaces; (2) photonic sintering quickly cures the deposited layer, avoiding the overheating of the substrate. To validate the manufacturing process, we printed strain gauges with conventional geometry on polyvinyl chloride (PVC) conduits. The entire manufacturing process, included sensor wiring and optional encapsulation, is performed at room temperature, compatible with the plastic surface. At the end of the process, the measured thickness of the printed sensor was 8.72 µm on average, the volume resistivity was evaluated 40 µΩ∙cm, and the thermal coefficient resistance was measured 0.150 %/°C. The average resistance was (71 ± 7) Ω and the gauge factor was found to be 2.42 on average.