Wearable sensor technologies are critical for out-of-hospital personalized medicine, enabling continuous or intermittent health monitoring. Key challenges include the miniaturization of flexible sensors and ensuring patient comfort while maintaining optimal electrical and mechanical performance.

To investigate the use of metallized, electrospun polymer fiber electrodes for producing 3D electrode structures with optimized surface roughness and large effective surface areas, aimed at reducing interface impedance.

A PMMA polymer solution with three different concentrations was processed via electrospinning. A concentration of 3.5 wt.% was chosen as optimal to avoid beaded fibers. The electrospun fibers were metallized and characterized through scanning electron microscopy (SEM) and electrochemical impedance spectroscopy (EIS). Impedance data were modeled using ZView software.

The SEM and EIS analysis showed pronounced surface roughness effects in the impedance data, but existing ZView elements did not model this well. The interfacial impedances were unexpectedly high, indicating that further optimization of the fabrication and modeling processes is needed.

Despite some promising surface roughness effects, the electrospun and metallized electrode structures exhibited large interface impedances. Further research is required to optimize these structures for practical use in wearable sensors.