We have developed a process for producing fine, very flexible microwires suitable for use as small signal leadwires or nerve electrodes. The process incorporates metallization of high-performance monofilament polymer fibers to yield electrically conductive fibers with greatly improved flexibility over solid metal wires of similar strength. The metallization layers are produced by serial vacuum deposition of a 0.3 μm thick coating of three metals, titanium-tungsten (Ti/W), gold (Au), and platinum (Pt), onto monofilament, poly-p-phenyl-terephthalate aramid fibers (Kevlar®). The metallized fibers are then insulated with an approx. 1 μm thick layer of silicone elastomer. The result is a microlead with high electrical conductivity (linear resistance = 30 Ω/cm), desirable interfacial properties, excellent mechanical stability and extremely high flexibility. These physical characteristics are appropriate for application as signal leadwires or recording/stimulating electrodes where small size and high flexibility are paramount. In this paper we report on the electrical and mechanical properties of these metallized fibers and demonstrate their use as intrafascicular electrodes for recording multi-unit neural activity in feline peripheral nerves.
