Ultra-Thin Soft Pneumatic Actuation for Minimally Invasive Neural Interfacing

Soft-robotic fluidic actuation allows dynamic control of the shape and position of ultra-flexible bioelectronic implants inside the body. While several actuation approaches have been proposed, all face significant limitations preventing clinical translation. Here, the use of laser-based fabrication techniques for selective welding of Parylene C to create fluidic actuation chambers capable of withstanding high pressures over repeated actuations is explored. The ultra-thin Parylene C fluidic chamber design with an electrode array for peripheral nerve interfacing is integrated, serving as a proof-of-concept for Parylene C-only fluidic actuation. Through thermoforming, it is molds Parylene C into a cuff which straightens and stiffens under fluidic pressure to aid implantation, before wrapping around the nerve bundle during depressurization. This is demonstrated on the sciatic nerve of a rodent model, achieving good electrophysiological recording resolution due to the conformal wrapping of the cuff. With the development of ultra-thin Parylene C based fluidic systems, it is aimed to push the boundaries of bioelectronic systems, offering new possibilities for monolithically integrated, minimally invasive interfacing. © 2025 The Author(s). Advanced Materials Technologies published by Wiley-VCH GmbH.