A Cost-Effective and Easy-to-Fabricate Conductive Velcro Dry Electrode for Durable and High-Performance Biopotential Acquisition

Compared with the traditional gel electrode, the dry electrode is being taken more seriously in bioelectrical recording because of its easy preparation, long-lasting ability, and reusability. However, the commonly used dry AgCl electrodes and silver cloth electrodes are generally hard to record through hair due to their flat contact surface. Claw electrodes can contact skin through hair on the head and body, but the internal claw structure is relatively hard and causes discomfort after being worn for a few hours. Here, we report a conductive Velcro electrode (CVE) with an elastic hook hair structure, which can collect biopotential through body hair. The elastic hooks greatly reduce discomfort after long-time wearing and can even be worn all day. The CVE electrode is fabricated by one-step immersion in conductive silver paste based on the cost-effective commercial Velcro, forming a uniform and durable conductive coating on a cluster of hook microstructures. The electrode shows excellent properties, including low impedance (15.88 kΩ @ 10 Hz), high signal-to-noise ratio (16.0 dB), strong water resistance, and mechanical resistance. After washing in laundry detergent, the impedance of CVE is still 16% lower than the commercial AgCl electrodes. To verify the mechanical strength and recovery capability, we conducted cyclic compression experiments. The results show that the displacement change of the electrode hook hair after 50 compression cycles was still less than 1%. This electrode provides a universal acquisition scheme, including effective acquisition of different parts of the body with or without hair. Finally, the gesture recognition from electromyography (EMG) by the CVE electrode was applied with accuracy above 90%. The CVE proposed in this study has great potential and promise in various human–machine interface (HMI) applications that employ surface biopotential signals on the body or head with hair.