Biometric electrode system and method of manufacture

A method for manufacturing an electrode system, the method comprising:

• providing a substrate comprising a set of conductive leads;
• coupling the substrate to fabric of a garment with a first bonding layer;
• forming an assembly comprising a non-conductive material layer coupled to a first broad surface of a fabric patch and a second bonding layer coupled to the second broad surface of the fabric patch;
• cutting a set of openings through the assembly;
• sealing the substrate within the first bonding layer and the second bonding layer with at least a portion of the set of conductive leads exposed through the set of openings;
• and
• coupling a volume of conductive polymer to each of the set of conductive leads, thereby forming a set of biosensing contacts coupled to the set of conductive leads and to the non-conductive material layer.

A method for manufacturing an electrode system, the method comprising:

• providing a substrate comprising a signal communication layer including a set of conductive leads;
• providing a non-conductive material layer having a set of openings corresponding to positions of at least a portion of each of the set of conductive leads;
• coupling a volume of conductive polymer within each of the set of openings of the non-conductive material layer, thereby forming a set of biosensing contacts with positions corresponding to positions of the set of conductive leads;
• forming a recess at a surface of each of the set of biosensing contacts;
• and
• coupling the non-conductive material layer to the substrate with a bonding layer, with a conductive polymer material coupled between the recesses of the set of biosensing contacts and the set of conductive leads.