Reusable, Fully Integrated Sweat Monitor Band with Peel‐and‐Stick‐Replacement Printed Microfluidic Sensor

Abstract This paper presents a continuous monitor for local sweat rate consisting of a fully reusable, wearable band with an integrated electronics module and a disposable, peel‐and‐stick‐replacement microfluidic sensor with printed electrodes. Local sweat rate sensors on specific skin sites have the potential to inform hydration strategies, with many devices recently introduced in the academic domain and even a few in the commercial domain. Here, several challenges in the design of sweat sensing systems are addressed: high reusability with minimal single‐use material, robust interfacing with the single‐use component in both electrical and fluidic pathways, implementation of scalable, roll‐to‐roll screen printing processes, and integration of precise measurements with continuous, wireless readout. Finally, the device is demonstrated on‐body during environmental heat and cycling exercise. In the near future, it is expected that this device will enable the academic study of sweat rate, and eventually, help make this biometric accessible to those such as workers and athletes in harsh environments.