Evaluation of 3D-Printed Dry Electrodes for Surface Electromyography in Dynamic Muscle Assessment

Surface electromyography (sEMG) is widely used to assess muscle activity in clinical and research settings. However, while conventional wet electrodes have advanced considerably in recent years, they are often limited by disposability, reduced comfort, and limited reusability. Recent advances in additive manufacturing provide opportunities to fabricate customizable, low-cost dry electrodes using conductive filaments. This study aimed to evaluate the feasibility and signal performance of in-house-fabricated 3D-printed sEMG electrodes made from three commercially available conductive filaments, (Fili, Filaflex, and Proto-Pasta) differing in base polymer and resistivity, and compared their performance with standard wet electrodes. Surface electrodes were placed over the biceps brachii muscle, and EMG signals were recorded during concentric–eccentric elbow flexion under three loading conditions (3, 5, and 7 kg). Signal quality was assessed using EMG amplitude, signal-to-noise ratio (SNR), and background noise. The results showed no significant differences in SNR or background noise between the 3D-printed electrodes and standard wet electrodes. Among the tested materials, Proto-Pasta electrodes produced the highest mean EMG amplitudes, while Filaflex electrodes showed slightly lower background noise, although these differences were not statistically significant. Overall, the findings indicate that in-house-fabricated 3D-printed electrodes can provide signal quality comparable to conventional wet electrodes, supporting their potential use as low-cost and customizable alternatives for sEMG applications in research and wearable monitoring systems.