A groundbreaking heart monitoring system that merges 3D printing, artificial intelligence, and a gel-free electrode design is poised to revolutionize cardiac diagnostics. Developed by researchers at Simon Fraser University’s (SFU) School of Mechatronic Systems Engineering, the system features reusable, dry 3D-printed electrodes shaped like origami and embedded in a soft, flexible chest belt. The unique folding structure uses gentle suction to adhere securely to the skin, eliminating the need for traditional sticky patches and conductive gel. The electrodes are made using a carbon-based ink that conducts the heart’s electrical signals directly to a wearable device equipped with AI software capable of pre-diagnosing up to 10 types of arrhythmias—abnormal heart rhythms. This real-time analysis allows for faster, more accurate detection, with results sent electronically to physicians for final review. “Current ECG testing depends on single-use gel-based patches that can dry out, fall off, and require manual interpretation by doctors,” says Woo Soo Kim, professor at SFU’s School of Mechatronic Systems Engineering. “This process is time-consuming, generates significant medical waste, and can be uncomfortable for patients. Our dry electrodes are just as accurate, more comfortable, easier to use, and can be cleaned and reused—drastically reducing environmental impact.” The team, led by post-doctoral researcher Yiting Chen, tested the system with frontline nurses from Vancouver General Hospital’s cardiac monitoring unit. Feedback indicated that the new design significantly improves patient comfort and compliance during extended monitoring—especially compared to bulky, traditional Holter monitors. A key advantage of the origami-style electrode is its self-resealing function. If the electrode loosens during use, users can simply press down to reestablish the seal, avoiding the need to reapply gel or reposition sticky patches. According to the European Heart Rhythm Association, one in three people worldwide will develop a cardiac arrhythmia during their lifetime, with atrial fibrillation—the most common type—projected to rise by over 60% globally by 2050. Kim emphasizes the system’s potential to expand access to heart health monitoring, particularly in underserved areas. “This tool is designed to be affordable, easy to use, and portable,” he says. “We envision it being used in remote communities, including First Nations populations, where access to medical professionals and diagnostic equipment is limited. People could take their own readings, the AI would provide an early assessment, and the results could be shared with a doctor for confirmation.” The research, published in Biosensors and Bioelectronics, highlights the system’s dual focus on sustainability and accessibility. The team is now working to refine the AI’s diagnostic accuracy and reduce the size of the 3D-printed electrode to one-third of its current height, making it even more discreet and user-friendly.