Advances in microneedle electrodes for electromyography acquisition in sports rehabilitation

Abstract Electromyography (EMG) is widely used in sports rehabilitation to evaluate muscle activation, coordination, fatigue, and functional recovery, yet reliable recording remains limited by the electrode-skin interface during repeated motion and prolonged wear. Microneedle electrodes offer a distinct interface strategy by penetrating the stratum corneum and forming lower-impedance, more stable electrical contact than conventional wet or dry electrodes. This review discusses microneedle electrodes for EMG acquisition in sports rehabilitation from a design-to-application perspective. We first clarify the interface requirements of EMG recording in rehabilitation settings and the technical rationale for using microneedle interfaces. We then summarize material and structural design strategies in silicon-, polymer-, and metal-based systems, focusing on how they balance penetration capability, mechanical compliance, stretchability, conductivity, and recording stability. Fabrication routes are further examined in terms of material-structure-process coupling, followed by applications in static assessment, dynamic motion monitoring, and clinical rehabilitation evaluation. This review integrates interface requirements, design, manufacturing, and validation to provide a structured overview of microneedle EMG electrodes' capabilities and limitations for sports rehabilitation.