Multi-Layer Brain-Mimicking Phantom for Replicating Dura and Pia Membrane Dimpling and Rupture Properties During Neural Interface Implantation

Development of novel neural interfaces faces buckling challenges and heavily relies on trial-and-error tests via in vivo animal brain insertions for design optimizations towards the minimal-damaging version for enhanced recording and stimulation outcome. To enable low-cost and fast-turnaround neural interface development and to enable previously impossible insertions via new understanding of the cutting process, this study developed a reproducible, multi-layer brain-mimicking phantom designed to replicate the rodent pia and dura mater dimpling and rupture force performance observed during in vivo tests. The phantom was composed of a 0.5% (w/v) agarose cortex layer, a 1.01% (w/v) agarose pia mater layer, and a pre-stretched polyvinyl chloride (PVC) dura mater layer, assembled via easily duplicable benchtop protocols. Using a cantilever-beam force measurement system, rupture force and dimpling depth were quantified across microwires of varying diameters (12-100 m), materials (tungsten, stainless steel), and tip geometries, as well as segmented silicon probe shanks. Phantom test results closely matched in vivo Sprague-Dawley rat data, validating the performance of the developed multi-layer phantom. At the same time, phantom insertion trial variability was substantially lower than in vivo tests, enabling a repeatable, low-cost, early-stage screening platform of novel electrode designs. The phantoms modular design also allowed tuning of layer thickness and stifness of each layer for diferent species or devices, ofering a validated customizable testing platform to accelerate novel neural implant development and reduce animal use.