A flexible catheter-based sensor array for upper airway soft tissues pressure monitoring

Obstructive sleep apnea is a globally prevalent concern with significant health impacts, especially when coupled with comorbidities. Accurate detection and localization of airway obstructions are crucial for effective diagnosis and treatment, which remains a challenge for traditional sleep monitoring methods. Here, we report a catheter-based flexible pressure sensor array that continuously monitors soft tissue pressure in the upper airway and facilitates at the millimeter level. The sensor’s design and versatile 3D femtosecond laser fabrication process enable adaptation to diverse materials and applications. In vitro testing demonstrates high sensitivity (38.1 Ω/mmHg) and excellent stability. The sensor array effectively monitors distributed airway pressure and accurately identifies obstructions in an obstructive sleep apnea animal model. In this work, we highlight the potential of this catheter-based sensor array for long-term, continuous upper airway pressure monitoring and its prospective applications in other medical devices for pressure measurement in human body cavities.