Aerosol jet printing (AJP) technology has emerged as a transformative tool in neuroprosthetic device development, offering high accuracy and versatility in fabricating complex and miniaturized structures, which are essential for advanced neural interfaces. This review explores the fundamental principles of AJP, highlighting its unique aerosol generation and concentrated deposition mechanisms, which facilitate the use of different materials on a variety of substrates. The advantages of AJP, including its device scalability, ability to print on flexible and stretchable substrates, and compatibility with a wide range of biocompatible materials, are examined in the context of neuroprosthetic applications. Key implementations, such as the fabrication of neural interfaces, the development of microelectrode arrays, and the integration with flexible electronics, are discussed, showcasing the potential of AJP to revolutionize neuroprosthetic devices. Additionally, this review addresses the challenges of biocompatibility and technical limitations, such as the long-term stability of electroconductive traces. The review concludes with a discussion of future directions and innovations, emphasizing the realization of sensorized prosthetic limbs through the incorporation of tactile sensors, the integration of biosensors for monitoring physiological parameters, and the development of intelligent prostheses. These prospects underscore the role of AJP in the advancement of neuroprosthetic applications and its pathway toward clinical translation and commercialization.

Electromyographic (EMG) sensors are essential tools for analyzing muscle activity, but traditional designs often face challenges such as motion artifacts, signal variability, and limited wearability. This study introduces a novel EMG sensor fabricated using Aerosol Jet Printing (AJP) technology that addresses these limitations with a focus on precision, flexibility, and stability. The innovative sensor design minimizes air interposition at the skin–electrode interface, thereby reducing variability and improving signal quality. AJP enables the precise deposition of conductive materials onto flexible substrates, achieving a thinner and more conformable sensor that enhances user comfort and wearability. Performance testing compared the novel sensor to commercially available alternatives, highlighting its superior impedance stability across frequencies, even under mechanical stress. Physiological validation on a human participant confirmed the sensor’s ability to accurately capture muscle activity during rest and voluntary contractions, with clear differentiation between low and high activity states. The findings highlight the sensor’s potential for diverse applications, such as clinical diagnostics, rehabilitation, and sports performance monitoring. This work establishes AJP technology as a novel approach for designing wearable EMG sensors, providing a pathway for further advancements in miniaturization, strain-insensitive designs, and real-world deployment. Future research will explore optimization for broader applications and larger populations.

This research focuses on the design, fabrication and testing of a compact, flexible 4-element array using Aerosol jet printing technology (AJP). The array operates at ISM-band 2.45 GHz for on-body RF energy harvesting applications (RFEH). The optimized array was printed on a flexible polyimide substrate with compact dimensions, where each element measures 30 x 16 mm ²• The simulated results were validated through testing, which exhibit good agreement, indicating that AJP is a precise and effective technique for printing high-resolution, conformal and flexible antennas. The design and optimization of the rectifier were performed at 2.45 GHz to ensure seamless integration with each element of the proposed array. The rectifier analysis demonstrated good performances, achieving output voltage of 3.5 V and a power conversion efficiency of 76.8 % at 10 dBm input power with a 2 kΩ load. This potential marks the path for further advancements in RFEH applications.