Breast Shaped Electrodes For Mastitis

B2B concentric TENS/EMS electrodes for mastitis and lactation. Engineered with multi-petal die-cutting and low-shear hydrogel to map 3D mammary topography without electrical arcing.

These breast-shaped electrodes are highly specific neuromodulation interfaces designed for postpartum mammary tissue. Standard rectangular or square pads fail mechanically when applied to the three-dimensional hemisphere of the breast, causing edge-lifting and localized electrical burns. This substrate is structurally engineered using a multi-petal or concentric ring die-cut pattern, allowing a flat 2D lamination stack to physically contour to a 3D curved surface. We manufacture these specialized blanks for FemTech hardware developers, clinical lactation consultants, and postpartum rehabilitation distributors.

• Concentric Topographical Conforming

  Applying a continuous 2D flat adhesive to a 3D sphere forces the material to buckle, creating deep wrinkles. In electrotherapy, a wrinkle lifts the conductive hydrogel off the skin, generating an air gap. High-voltage pulses cross this gap as thermal arcs, causing severe localized point-burns. The radial die-cut slits act as mechanical strain-relief zones. When the pad is pressed onto the breast, the "petals" overlap or separate dynamically, maintaining 100% flat hydrogel contact across the curved topography and eliminating resistance focal points. 

   

• Areola Innervation Avoidance 

  The areola and nipple complex contain highly dense sensory nerve endings. Passing direct electrical currents (TENS/EMS) through this specific zone generates acute pain rather than therapeutic relief. The core of this pad features a die-cut central void (typically 30mm to 40mm). This physical absence of conductive material acts as an absolute electrical insulator by omission. The current vector is forced entirely into the surrounding mammary ducts and pectoralis fascia, targeting the glandular blockage while bypassing the sensitive central nerve clusters.

   

• Low-Shear Hydrogel Rheology 

  During active mastitis or engorgement, the epidermis stretches thin and experiences severe localized inflammation. Applying a standard 3.5N high-tack sports gel to this tissue will mechanically strip the stratum corneum upon removal. We restrict the carbomer cross-linking density within the hydrogel matrix to cap the mechanical peel force at 2.0N maximum. This sacrifices the pad's multi-day lifespan to ensure the physical extraction process does not inflict mechanical trauma on compromised postpartum skin.

• Rotary Die Customization: The substrate geometry can be modified from a full 360-degree concentric ring to a "C-shape" or crescent. This allows the pad to fit cleanly underneath standard breast pump flanges, enabling simultaneous electrical stimulation and mechanical vacuum pumping. 

• Logistics Routing : Base conductive coating and complex rotary die-cutting run in China. Terminal pin assembly, QA sorting, and moisture-barrier pouching route through our Vietnam hub to manage supply chain continuity and optimize FemTech hardware tariffs.

• Biocompatibility: The low-shear hydrogel is validated against ISO 10993-5 (Cytotoxicity) and ISO 10993-10 (Sensitization) limits. 

• Systems: Lamination and physical separation lines execute under audited ISO 13485:2016 frameworks.

B2B FemTech hardware developers can request concentric die-cut blanks to evaluate 3D topography conformity and hydrogel peel force. 

👉 [Request Breast Electrode Prototypes]

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