An adaptive wearable ultrasonic transducer based on 3D printing

Adaptive wearable ultrasound transducers (AWUTs) designed for irregular skin surfaces have gained significant attention in personalized medicine and smart rehabilitation. However, existing wearable devices struggle to achieve both dynamic skin conformity and unobstructed front electrodes, which are essential for enhancing ultrasound sensitivity. To address these challenges, we propose a method for fabricating AWUTs by integrating 3D origami structures with ultrasound transducer arrays, inspired by the origami folding mechanism. This method employs precision projection microstereolithography (PμSL) 3D printing technology to create origami structures with excellent deformability. Additionally, the stable electrical response and mechanical integrity of the multi-walled carbon nanotube (MWCNTs) and polydimethylsiloxane (PDMS) composite electrode provide high conductivity (4.76 S/cm),an elastic modulus of 1.1 Gpa, and high flexibility. These properties reduce ultrasound energy loss during propagation and enhance the accuracy of tissue characterization and diagnosis. The developed AWUT has a center frequency of 3.43 MHz and a ﹣6dB bandwidth of 45.28%. The potential application of the AWUT for noninvasive, continuous, and precise monitoring of arterial blood pressure was validated through imaging of human carotid arteries and blood pressure monitoring.