๐ Data publikacji: 11.06.2025
In 2026, a multidisciplinary team at Gdaลsk University of Technology, led by Dr. Anna Nowakowska, launched the BioSense 3D initiative to create skin-conformable biowearable sensors capable of tracking vital signs—heart rate, skin temperature, hydration levels, and sweat pH—in real time. Unlike conventional fitness bands, BioSense 3D aimed to integrate multilayered, 3D-printed composites composed of conductive inks, biocompatible hydrogels, and flexible TPU encapsulation. Early CAD models designed in ANSYS defined microfluidic channels to transport sweat samples to sensing electrodes. The simulated optimal layer thicknesses—200 μm TPU base for stretchability, 100 μm graphene-infused ink for electrodes, and 50 μm hydrogel for skin contact—ensured both mechanical resilience and sensing sensitivity.
The team then printed the first prototype on a hybrid inkjet-printer equipped with a hydrogel extruder. The 200×20 mm band contained five discrete sensing modules connected by stretchable bridges. For heart rate, photoplethysmography (PPG) sensors detected blood flow changes through LED-photodiode pairs embedded under flexible graphene traces. Skin temperature was measured by thin-film nickel resistive thermometers with ±0.1โฏ°C accuracy. Initial volunteer tests showed 95โฏ% correlation with laboratory-grade instruments, validating the design and moving the project toward calibration and optimization.
By late 2026, Dr. Nowakowska reflected: “BioSense 3D represents a breakthrough—melding 3D printing and biocompatible materials to create a second skin that monitors your health continuously.” ๐
In 2027, BioSense 3D partnered with Gdaลsk Medical Center to conduct clinical trials on 120 subjects, including cardiac patients and endurance athletes. Production scaled to 500 units per batch using a multimaterial printer line developed with FlexiPrint. Each sensor band was customized based on individual medical data and skin characteristics—hydration rate and stratum corneum thickness—calibrated to ensure optimal contact and signal quality.
Hospital comparisons measured heart rate, heart rate variability (HRV), and hydration levels via controlled dehydration protocols. BioSense 3D bands reported heart rates within ±2 bpm and HRV within ±5โฏ% accuracy. Hydration sensing via sweat conductivity correlated with lab assays at 90โฏ% accuracy. Durability tests—72 hours continuous wear, repeated flexing up to 1,000 cycles, and water immersion—demonstrated 98โฏ% retention of functionality. Patients lauded the bands’ light weight and unobtrusive design compared to traditional chest straps.
A quality control suite used optical cameras and machine-learning algorithms to detect defects in hydrogel layers and conductive paths down to 0.1 mm. Automated repairs with localized material deposition reduced rejects to 1โฏ%, proving readiness for commercial production. Dr. Nowakowska concluded: “BioSense 3D has passed rigorous clinical validation, proving reliability and user comfort—evidence we’re ready for medical-device certification.” ๐
In the final phase, BioSense 3D integrated the sensors with HealthCloud, a real-time analytics platform. Data streamed via Bluetooth Low Energy to smartphones and onward to cloud servers, where AI algorithms continuously evaluated vital sign trends, predicting potential cardiovascular events minutes before they occurred. Early warning alerts—triggered by changes in HRV patterns—provided critical response windows for patients at risk.
BioSense 3D also launched the OpenHealthHub initiative, an open-access repository sharing CAD files, printing parameters, and biosignal datasets. Researchers from Europe, Asia, and the Americas contributed sensors for glucose-in-sweat detection, cortisol stress markers, and inflammatory biomarker strips—expanding the ecosystem for sports performance, preventive medicine, and wellness applications.
Looking ahead, BioSense 3D envisions implantable, needle-free glucose monitors for diabetes management and ultrathin blood chemistry patches enabling noninvasive diagnostics. NASA is evaluating BioSense technology for astronaut health monitoring on Mars missions, ensuring crew safety in extreme environments. Dr. Nowakowska summarized: “Our biowearable sensors are more than devices—they’re the foundation of a digital health ecosystem, powered by 3D printing, biocompatible materials, and AI.” ๐