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Making Surface Electrodes with Aluminum Foil & Cloth

1. Cut a piece of Aluminum foil that is 4 times the size of the electrode. For example, for 2”x2” electrode, start with 4”x4” Aluminum piece. Fold it in 4 sections and then open it as shown. To one section, tape a lead-wire-connector (taken from a commercial electrode) so that its bare wire is inside touching the foil. Also tape the bare wire section to the foil once or twice. Now fold the foil twice so taped portion in on the inside.

2. Cut a piece of cloth that is 1/4 inch-more-on-all-sides than twice the size of electrode. For example, for 2”x2” electrode, instead of 2”x4”, get 2.5”x5” piece of cloth (or two pieces of 2.5”x2.5”). Fold it in the middle and then put Liquid-Stitch glue on four edges as shown. This glue should be a bit less than 1/4” wide so the aluminum foil can be placed inside the glued edges.

3. Place the folded Aluminum foil, with lead connector attached, on the cloth as shown.

4. Fold the cloth over that let stitch glue soak in to the other edges. Try to squeeze glue in rather than out. Let the cloth dry for about 24 hours.

5. Cut all the edges of the cloth about 1/8” and round the corners so that finished electrode looks smooth and without any frayed threads, as shown below.

6. With Liquid Stitch, affix an additional layer of clothing on one side of electrode and mark this side ‘I’ (for In) since it will be on the inside touching the skin. Let the electrode dry over 24 hours. Trim cloth edges like before. Other side is to be marked ‘O’ (for Out) and will be visible during treatment..

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