IntroductionWide use of miniaturized and flexible microwire electrodes faces challenges of wire buckling against the brain membrane layers. The field lacks quantitative understanding of such buckling phenomena, especially on the effective length factor, which is required to determine the wire’s critical buckling load.MethodsThis study presents an experimental investigation into the buckling behavior of tungsten microwire electrodes during implantation through dura and pia mater layers using a validated multilayer brain-mimicking phantom. Microwires with three diameters (25.4, 50.8, and 76.2 µm) and different tip geometries—including blunt, beveled, and electrochemically (conical) sharpened profiles—were evaluated under controlled axial insertion. Critical buckling length, insertion outcomes (buckled/penetrated), and rupture/buckling force were quantified across the experimental dataset. Buckling behavior was analyzed using the Euler column framework with experimentally estimated effective length factors (Kˆ) to represent each unique membrane-wire tip boundary interaction.ResultsResults indicated that wire diameter strongly influences buckling resistance, with larger diameters yielding quartic (fourth order) higher critical buckling load of the electrode, whereas the corresponding membrane rupture force only increases linearly with the diameter. But smaller microwires tend to anchor better against the brain membrane, generating a more stable wire-membrane interface closer to the ideal pin end condition. Tip geometry also significantly affected rupture force and insertion stability; conical tips dramatically reduced the membrane rupture force with less variance. In general, tip sharpening choice for small microwires should focus on optimizing tips anchoring mechanism and minimizing rupture force uncertainty introduced by tip asymmetry while thick microwires mainly benefit from membrane rupture force reduction. For theoretical prediction of a microwire electrode’s critical buckling load based on Euler’s buckling equation, unlike conventional fixed-pinned assumption (K = 0.7), experimentally measured effective length factors ranged from approximately 0.72 – 0.82.DiscussionDesigning with ≈ 0.8 provides a conservative estimate that may reduce the risk of buckling under membrane penetration conditions compared to the commonly assumed fixed-pinned value of 0.7. These findings provide quantitative design guidance for optimizing microwire geometry and offer a validated benchtop framework for predicting buckling-limited insertion performance in neural interface applications.
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