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Additive manufacturing technologies increasingly revolutionize current production techniques for object manufacturing. Particularly, fused deposition modeling (FDM) strongly impacts production processes by enabling the cost‐effective and efficient creation of structures with complex designs and innovative geometries. The use of conductive filaments in FDM printing is paving the way for the advancement of entirely printed sensors and circuits, although this domain is still in its early stages. In this article, the design and production of bilayer deformable pressure sensors fabricated using conductive thermoplastic polyurethane are investigated. The potential to vary the mechanical and electrical characteristics of FDM‐printed components by adjusting printing parameters is explored. The influence of different levels of material infill (20%, 50%, and 100%) and different contact geometries between layers (domes, pyramids, and cylinders) is studied. Electromechanical tests are carried out to characterize the sensor, applying pressures up to 22 kPa. The 3D‐printed pressure sensors demonstrate tunable mechanical and electrical sensitivities at different infill values, with the highest value of −6.3 kPa−1 achieved by using a pyramid layer at 100% infill. Sensor outputs registered during cyclic tests show reproducible responses with a wide range of sensitivity, paving the way for applicability in recording both static and periodic pressure changes.

Goal: To evaluate the suitability of seismocardiogram (SCG) and gyrocardiogram (GCG) recorded at the skin level to classify aortic stenosis (AS) patients from healthy volunteers, and to determine the optimal sensor position for the classification. Methods: SCG and GCG were recorded along three axes at five chest locations of fifteen healthy subjects and AS patients. Signal frames underwent feature extraction in frequency and time-frequency domains. Then, binary classification was performed through three machine learning and three deep learning methods, considering SCG, GCG, and their combination. Results: The highest classification accuracies were achieved using Support Vector Machine (SVM) classifier, with the best sensor locations being at the mitral valve for SCG signals (92.3% accuracy) and at the pulmonary valve for GCG (92.1%). Combining SCG and GCG data allows for further improvement in the achievable accuracy (93.5%). Jointly exploiting SCG and GCG signals and both SVM- and ResNet18-based classifiers, 40 s of monitoring allows for reaching 97.2% accuracy with a single sensor on the pulmonary valve. Conclusions: Combining SCG and GCG with adequate machine learning and deep learning classifiers allows reliable classification of AS patients.

Diabetes is one of the most common diseases worldwide, with an increasing number of people affected. Insulin therapy is still the major treatment for both Type 1 and Type 2 diabetes and has evolved from bulky syringes to modern insulin pens introduced in 1985. An insulin pen consists of three major parts: a cartridge, a single-use pen needle (PN), and a precision dosing mechanism. Initially, PNs were long and thick, causing great discomfort and concern. Thanks to advances in design, shorter and thinner needles have appeared on the market, improving patient acceptability and pain perception. Studies highlight the influence of PN geometry and other characteristics on injection-related pain, including length, diameter, bevel design, and hub. Despite a lack of specific international regulations for PN geometry, scientific publications have focused on exploring different PNs’ characteristics to optimize patient comfort and reduce pain. To guide the selection of suitable PNs, this review provides a round-up of literature research findings on the impact of PN geometry on pain perception and patient acceptability. Specifically, it provides an overview of the PN manufacturing process, current international regulations, and the state-of-the-art research on PN geometry affecting pain perception.

This study focuses on the integration and validation of a filtering face piece 3 (FFP3) facemask module for monitoring breathing activity in industrial environments. The key objective is to ensure accurate, real-time respiratory rate (RR) monitoring while maintaining workers’ comfort. RR monitoring is conducted through temperature variations detected using temperature sensors tested in two configurations: sensor t1, integrated inside the exhalation valve and necessitating structural mask modifications, and sensor t2, mounted externally in a 3D-printed structure, thus preserving its certification as a piece of personal protective equipment (PPE). Ten healthy volunteers participated in static and dynamic tests, simulating typical daily life and industrial occupational activities while wearing the breathing activity monitoring module and a chest strap as a reference instrument. These tests were carried out in both indoor and outdoor settings. The results demonstrate comparable mean absolute error (MAE) for t1 and t2 in both indoor (i.e., 0.31 bpm and 0.34 bpm) and outdoor conditions (i.e., 0.43 bpm and 0.83 bpm). During simulated working activities, both sensors showed consistency with MAE values in static tests and were not influenced by motion artifacts, with more than 97% of RR estimated errors within ±2 bpm. These findings demonstrate the effectiveness of integrating a smart module into protective masks, enhancing occupational health monitoring by providing continuous and precise RR data without requiring additional wearable devices.

Growing evidence suggests that respiratory frequency (fR) is a valid marker of effort during high-intensity exercise, including sports of an intermittent nature, like soccer. However, very few attempts have been made so far to monitor fR in soccer with unobtrusive devices. This study assessed the validity of three strain-based commercial wearable devices measuring fR during soccer-specific movements. On two separate visits to the soccer pitch, 15 players performed a 30 min validation protocol wearing either a ComfTech® (CT) vest or a BioharnessTM (BH) 3.0 strap and a Tyme WearTM (TW) vest. fR was extracted from the respiratory waveform of the three commercial devices with custom-made algorithms and compared with that recorded with a reference face mask. The fR time course of the commercial devices generally resembled that of the reference system. The mean absolute percentage error was, on average, 7.03% for CT, 8.65% for TW, and 14.60% for BH for the breath-by-breath comparison and 1.85% for CT, 3.27% for TW, and 7.30% for BH when comparison with the reference system was made in 30 s windows. Despite the challenging measurement scenario, our findings show that some of the currently available wearable sensors are indeed suitable to unobtrusively measure fR in soccer.

Respiratory rate (fR) monitoring through wearable devices is crucial in several scenarios, providing insights into well-being and sports performance while minimizing interference with daily activities. Strain sensors embedded into garments stand out but require thorough investigation for optimal deployment. Optimal sensor positioning is often overlooked, and when addressed, the quality of the respiratory signal is neglected. Additionally, sensor metrological characterization after sensor integration is often omitted. In this study, we present the design, development, and feasibility assessment of a smart t-shirt embedded with two flexible sensors for fR monitoring. Guided by a motion capture system, optimal sensor design and position on the chest wall were defined, considering both signal magnitude and quality. The sensors were developed, embedded into the wearable system, and metrologically characterized, demonstrating a remarkable response to both static (sensitivity 9.4 Ω⋅%−1 and 9.1 Ω⋅%−1 for sensor A and sensor B, respectively) and cyclic loads (min. hysteresis span 20.4% at 36 bpm obtained for sensor A). The feasibility of the wearable system was assessed on healthy volunteers both under static and dynamic conditions (such as running, walking, and climbing stairs). A mean absolute error of 0.32 bpm was obtained by averaging all subjects and tests using the combination of the two sensors. This value was lower than that obtained using both sensor A (0.53 bpm) and sensor B (0.78 bpm) individually. Our study highlights the importance of signal amplitude and quality in optimal sensor placement evaluation, as well as the characterization of the embedded sensors for metrological assessment.

The identification of respiratory patterns based on the movement of the chest wall can assist in monitoring an individual’s health status, particularly those with neuromuscular disorders, such as hemiplegia and Duchenne muscular dystrophy. Thoraco-abdominal asynchrony (TAA) refers to the lack of coordination between the rib cage and abdominal movements, characterized by a time delay in their expansion. Motion capture systems, like optoelectronic plethysmography (OEP), are commonly employed to assess these asynchronous movements. However, alternative technologies able to capture chest wall movements without physical contact, such as RGB digital cameras and time-of-flight digital cameras, can also be utilized due to their accessibility, affordability, and non-invasive nature. This study explores the possibility of using a single RGB digital camera to record the kinematics of the thoracic and abdominal regions by placing four non-reflective markers on the torso. In order to choose the positions of these markers, we previously investigated the movements of 89 chest wall landmarks using OEP. Laboratory tests and volunteer experiments were conducted to assess the viability of the proposed system in capturing the kinematics of the chest wall and estimating various time-related respiratory parameters (i.e., fR, Ti, Te, and Ttot) as well as TAA indexes. The results demonstrate a high level of agreement between the detected chest wall kinematics and the reference data. Furthermore, the system shows promising potential in estimating time-related respiratory parameters and identifying phase shifts indicative of TAA, thus suggesting its feasibility in detecting abnormal chest wall movements without physical contact with a single RGB camera.

The measurement of physiological parameters is fundamental to assess the health status of an individual. The contactless monitoring of vital signs may provide benefits in various fields of application, from healthcare and clinical setting to occupational and sports scenarios. Recent research has been focused on the potentiality of camera-based systems working in the visible range (380–750 nm) for estimating vital signs by capturing subtle color changes or motions caused by physiological activities but invisible to human eyes. These quantities are typically extracted from videos framing some exposed body areas (e.g., face, torso, and hands) with adequate post-processing algorithms. In this review, we provided an overview of the physiological and technical aspects behind the estimation of vital signs like respiratory rate, heart rate, blood oxygen saturation, and blood pressure from digital images as well as the potential fields of application of these technologies. Per each vital sign, we provided the rationale for the measurement, a classification of the different techniques implemented for post-processing the original videos, and the main results obtained during various applications or in validation studies. The available evidence supports the premise of digital cameras as an unobtrusive and easy-to-use technology for physiological signs monitoring. Further research is needed to promote the advancements of the technology, allowing its application in a wide range of population and everyday life, fostering a biometrical holistic of the human body (BHOHB) approach.

Heart rate (HR) and respiratory rate (fR) can be estimated by processing videos framing the upper body and face regions without any physical contact with the subject. This paper proposed a technique for continuously monitoring HR and fR via a multi-ROI approach based on the spectral analysis of RGB video frames recorded with a mobile device (i.e., a smartphone’s camera). The respiratory signal was estimated by the motion of the chest, whereas the cardiac signal was retrieved from the pulsatile activity at the level of right and left cheeks and forehead. Videos were recorded from 18 healthy volunteers in four sessions with different user-camera distances (i.e., 0.5 m and 1.0 m) and illumination conditions (i.e., natural and artificial light). For HR estimation, three approaches were investigated based on single or multi-ROI approaches. A commercially available multiparametric device was used to record reference respiratory signals and electrocardiogram (ECG). The results demonstrated that the multi-ROI approach outperforms the single-ROI approach providing temporal trends of both the vital parameters comparable to those provided by the reference, with a mean absolute error (MAE) consistently below 1 breaths·min−1 for fR in all the scenarios, and a MAE between 0.7 bpm and 6 bpm for HR estimation, whose values increase at higher distances.

Respiratory monitoring is receiving growing interest in different fields of use, ranging from healthcare to occupational settings. Only recently, non-contact measuring systems have been developed to measure the respiratory rate (fR) over time, even in unconstrained environments. Promising methods rely on the analysis of video-frames features recorded from cameras. In this work, a low-cost and unobtrusive measuring system for respiratory pattern monitoring based on the analysis of RGB images recorded from a consumer-grade camera is proposed. The system allows (i) the automatized tracking of the chest movements caused by breathing, (ii) the extraction of the breathing signal from images with methods based on optical flow (FO) and RGB analysis, (iii) the elimination of breathing-unrelated events from the signal, (iv) the identification of possible apneas and, (v) the calculation of fR value every second. Unlike most of the work in the literature, the performances of the system have been tested in an unstructured environment considering user-camera distance and user posture as influencing factors. A total of 24 healthy volunteers were enrolled for the validation tests. Better performances were obtained when the users were in sitting position. FO method outperforms in all conditions. In the fR range 6 to 60 breaths/min (bpm), the FO allows measuring fR values with bias of −0.03 ± 1.38 bpm and −0.02 ± 1.92 bpm when compared to a reference wearable system with the user at 2 and 0.5 m from the camera, respectively.

During the last decades, tactile sensors based on different sensing principles have been developed due to the growing interest in robotics and, mainly, in medical applications. Several technological solutions have been employed to design tactile sensors; in particular, solutions based on microfabrication present several attractive features. Microfabrication technologies allow for developing miniaturized sensors with good performance in terms of metrological properties (e.g., accuracy, sensitivity, low power consumption, and frequency response). Small size and good metrological properties heighten the potential role of tactile sensors in medicine, making them especially attractive to be integrated in smart interfaces and microsurgical tools. This paper provides an overview of microfabricated tactile sensors, focusing on the mean principles of sensing, i.e., piezoresistive, piezoelectric and capacitive sensors. These sensors are employed for measuring contact properties, in particular force and pressure, in three main medical fields, i.e., prosthetics and artificial skin, minimal access surgery and smart interfaces for biomechanical analysis. The working principles and the metrological properties of the most promising tactile, microfabricated sensors are analyzed, together with their application in medicine. Finally, the new emerging technologies in these fields are briefly described.

Among all the vital signs, respiratory rate remains the least measured in several scenarios, mainly due to the intrusiveness of the sensors usually adopted. For this reason, all contactless monitoring systems are gaining increasing attention in this field. In this paper, we present a measuring system for contactless measurement of the respiratory pattern and the extraction of breath-by-breath respiratory rate. The system consists of a laptop’s built-in RGB camera and an algorithm for post-processing of acquired video data. From the recording of the chest movements of a subject, the analysis of the pixel intensity changes yields a waveform indicating respiratory pattern. The proposed system has been tested on 12 volunteers, both males and females seated in front of the webcam, wearing both slim-fit and loose-fit t-shirts. The pressure-drop signal recorded at the level of nostrils with a head-mounted wearable device was used as reference respiratory pattern. The two methods have been compared in terms of mean of absolute error, standard error, and percentage error. Additionally, a Bland−Altman plot was used to investigate the bias between methods. Results show the ability of the system to record accurate values of respiratory rate, with both slim-fit and loose-fit clothing. The measuring system shows better performance on females. Bland−Altman analysis showed a bias of −0.01 breaths · min − 1 , with respiratory rate values between 10 and 43 breaths · min − 1 . Promising performance has been found in the preliminary tests simulating tachypnea.

There is an ever-growing demand for measuring respiratory variables during a variety of applications, including monitoring in clinical and occupational settings, and during sporting activities and exercise. Special attention is devoted to the monitoring of respiratory rate because it is a vital sign, which responds to a variety of stressors. There are different methods for measuring respiratory rate, which can be classed as contact-based or contactless. The present paper provides an overview of the currently available contact-based methods for measuring respiratory rate. For these methods, the sensing element (or part of the instrument containing it) is attached to the subject’s body. Methods based upon the recording of respiratory airflow, sounds, air temperature, air humidity, air components, chest wall movements, and modulation of the cardiac activity are presented. Working principles, metrological characteristics, and applications in the respiratory monitoring field are presented to explore potential development and applicability for each method.

Application fields of micromachined devices are growing very rapidly due to the continuous improvement of three dimensional technologies of micro-fabrication. In particular, applications of micromachined sensors to monitor gas and liquid flows hold immense potential because of their valuable characteristics (e.g., low energy consumption, relatively good accuracy, the ability to measure very small flow, and small size). Moreover, the feedback provided by integrating microflow sensors to micro mass flow controllers is essential to deliver accurately set target small flows. This paper is a review of some application areas in the biomedical field of micromachined flow sensors, such as blood flow, respiratory monitoring, and drug delivery among others. Particular attention is dedicated to the description of the measurement principles utilized in early and current research. Finally, some observations about characteristics and issues of these devices are also reported.