Hybrid 3D Printing of a Nature‐Inspired Flexible Self‐Adhesive Biopatch for Multi‐Biosignal Sensing

Bioinspired skin adhesives are promising alternatives to traditional glue‐based skin patches for use in various skin‐attachable devices. However, the typical nano‐/microfabrication of these bioinspired microstructures provides limited manufacturing freedom over their performance, constraining their versatility and customization for widespread use. In this study, a hybrid 3D printing approach for fabricating a permeable skin patch is developed with adhesive miniaturized octopus‐like suckers (AMOS) for biosignal monitoring. The design and geometrical influences are investigated on the adhesion strength under different skin conditions (i.e., dry, wet, and hairy), permeability, and durability as well as proposed a biocompatible, stretchable, highly permeable, reusable, and conformable biopatch. Unlike commercially available biopatches that use chemical adhesives, the adhesion strength of an AMOS patch is customizable, does not cause skin irritation, and is comfortable for the wearer when worn for extended durations. The biopatch is tested in electromyogram, electrooculogram, and electrocardiogram signal measurement during a hand‐cycling experiment over extended durations that confirms its potential in extreme sport events. In addition to biosignal monitoring, 3D‐printed AMOS patches have broad applicability across various skin‐interfacing devices, including glucose and sweat monitoring, drug delivery, and wound healing. This approach offers a promising and highly customizable manufacturing solution for unlocking next‐generation skin‐attachable technologies. This article reports on a hybrid 3D printing approach to create a breathable skin patch with adhesive, miniaturized octopus‐like suckers for biosignal monitoring. The study examines how various microstructural designs and geometries affect adhesion strength, permeability, and durability. Notably, this approach utilizes off‐the‐shelf 3D printers to achieve high‐resolution, micro‐scale adhesive structures, paving the way for next‐generation skin‐worn devices.