Development of the NeuroTraining Stimulation Pad

The NeuroTraining stimulation pad has been at the core of the SensTrain development program from day one. We explored a wide range of materials and designs to achieve the ideal combination of comfort, adhesion, and performance.

We tested copper flexi-PCB, regular TENS pad materials, and various fabric-based solutions. Each material had its advantages, but none perfectly met our needs. Through repeated user-testing and by working with industry-experts in printed electronics we were able to find the right material – A thin fabric with high flexibility, breathability and comfort.

We also experimented with using hydrogels; both on the electrodes and across the pad, but found that they didn’t provide consistent conductivity or comfort. Additionally, we tested different electrode sizes – From 4mm to 12mm diameter, looking for an optimal balance between precision and surface coverage and ensuring users could discriminate between them.

Adhesion was another critical factor as it is key that the electrodes remain in good contact with the skin to ensure a clear and comfortable stimulation. We tried a range of acrylic and silicon-based adhesives before finding the perfect 3M product, which offers us the adhesion required while still being comfortable to wear and remove.

The result is a stimulation pad that is effective, comfortable, and reliable—supporting users in their neurotraining journey with SensTrain.

We then tested this on a range of people, upper and lower limb amputees, non-amputees, clinicians and the SensTrain team and found quite quickly that sensitivity between individuals, and across the relatively small area over which the pad sits.