Deformation Driven Suction Cups: A Mechanics-Based Approach to Wearable Electronics

Wearable electronics are emerging as essential tools for health monitoring, haptic feedback, and human-computer interactions. While stable contact at the device-body interface is critical for these applications, it remains challenging due to the skin's softness, roughness, and mechanical variability. Existing methods, such as grounding structures or adhesive tapes, often suffer from contact loss, limited repeatability, and restrictions on the types of electronics they can support. Suction-based adhesives offer a promising alternative by generating negative pressure without requiring tight bands or chemical adhesives. However, most existing cup designs rely on rigid-surface assumptions and overlook mechanical interactions between suction cups and skin. Inspired by traditional cupping therapies, we present a suction-based adhesive system that attaches through elastic deformation and recovery. Using analytical modeling, numerical simulations, and experiments, we present a mechanics-based framework showing how suction performance depends on cup geometry, substrate compliance, and interfacial adhesion. We show that cup geometry should be tailored to substrate stiffness. Wide, flat suction cups perform well on rigid surfaces but fail on soft ones like skin due to substrate intrusion into the chamber. Narrow and tall domes better preserve recoverable volume and generate stronger suction. To improve sealing on rough, dry skin, we introduce a soft, tacky interfacial layer informed by a contact mechanics model. Using our design principles for skin suction adhesives, we demonstrate secure attachment of rigid and flexible components including motion sensors, haptic actuators, and electrophysiological electrodes across diverse anatomical regions. These findings provide a fundamental basis for designing the next generation of skin-friendly adhesives for wearable electronics.