SUMMARY

Advanced manufacturing methods to produce flexible printed circuit boards (PCBs), nanomembrane biosensors, and wireless measurement systems have transformed healthcare monitoring and human-machine interfaces from large, stationary equipment to palm-sized wearables. These soft and flexible wearable systems can meet or exceed the data quality of clinical gold standards and provide new opportunities for at-home health monitoring without interfering with daily activities. However, these systems often suffer from long-term stability problems stemming from the fragility of thin film sensors along with adhesive degradation, electrode degradation, and mechanical failure. To combat these issues, this thesis focuses on novel manufacturing methods that can improve flexible biosensor robustness and provide better interfaces between flexible biosensors and measurement electronics. Methods discussed include direct sensor integration into flexible PCBs, laser processing techniques for rapid iteration of microscale structures, textile integration of sensors, and improved biosensor connection methods. Successful applications of these manufacturing methods are demonstrated in a cell culturing monitoring system, an upper-body exoskeleton, a postpartum health monitoring patch, neonatal monitoring systems, haptic feedback gloves, and smart face masks.