Exponential advancements in technology have turned ideas that once belonged to the realm of science fiction into reality. Until recently, controlling machines with one’s mind was a cybernetic fantasy, but brain-computer interface (BCI) technology now has a genuine potential to revolutionise medicine.
A BCI system enables direct communication between the brain and an external device by detecting and interpreting brain signals, then translating them into commands. These have been used for a range of applications, from moving a cursor on a screen to controlling a prosthetic limb or restoring lost senses. One use of BCI technology that is gaining major traction in the media is the restoration of movement to people who have lost motor control due to conditions such as paralysis, stroke, or spinal cord injury. Traditional therapies often struggle to repair or reroute damaged neural pathways, but BCIs offer a workaround by bypassing the injury altogether.
In January 2024, Neuralink implanted the first patient with its BCI following the receipt of an investigational device exemption from the FDA in May 2023, and in January 2025, Motif Neurotech won a funding grant from the UK government’s Advanced Research and Invention Agency to advance its therapeutic BCI technology for treating cognitive and psychiatric conditions. In Europe, Inbrain Neuroelectronics, Onward Medical, and CorTec have all made significant advances, while Australian company Synchron and Chinese StairMed continue to push boundaries for BCI across APAC.
While BCI implementation is in its nascent stages, the technology is already showing significant potential for growth. Grand View Research currently estimates that the BCI market could be worth $6.2bn by 2030, growing at a compound annual growth rate (CAGR) of 17.5%.
Human stories behind the science
In 2020, Keith Thomas was left paralysed from the chest down following a diving accident.
Participating in a clinical trial at Northwell Health’s Feinstein Institutes in New York, Thomas underwent a double neural bypass, a groundbreaking procedure to drive both motor commands and sensory feedback. Multiple electrode arrays were placed directly on his brain during a 15‑hour surgery, focusing on areas responsible for both movement and sensation, which were connected to a spinal stimulator and muscle electrode patches on his arm and hand. When Thomas thought about moving his arm, the BCI detected those neural signals, which were decoded by artificial intelligence (AI) and applied electrical pulses to the spinal cord and muscles to activate movement and restore feeling.His strength also continued to improve beyond baseline after the system was turned off, suggesting neurological recovery in addition to functional restoration
In March 2025, researchers at UCSF published in Cell the results of a clinically trialled BCI enabling a man paralysed by stroke to control a robotic arm. Notably, this system continued to function reliably for seven months with adjustment. These devices normally only function for a day or two due to challenges such as brain signal instability or electrode degradation. This case is significant as it shows us the potential for long-term stability and signals a leap forward in BCI resilience. With the adoption of AI, the interface remained precise and user‑friendly, reducing dependency on engineers. For individuals beset by paralysis, this could mean a future of agency and day‑to‑day autonomy.
Regaining autonomy is more than just being given the opportunity to move around, but also the ability to communicate and the right to self-expression. The third human recipient of Neuralink’s implant was a man with advanced ALS, Bradford (Brad) Smith. He made headlines by editing and posting a YouTube video entirely through his mind using the device implanted in his motor cortex. Smith learned to control a computer cursor using subtle tongue‑movement proxies, a neural strategy optimised by his subconscious. Using an AI-driven voice replicator trained on pre‑diagnosis recordings, Smith was also able to narrate the video in his original voice.
Early trials also suggest that BCIs might be able to help individuals with memory loss by reactivating or reinforcing neural circuits involved in memory formation and recall. For patients with severe depression or PTSD, BCIs could one day allow for targeted brain stimulation therapies that are more precise than current pharmaceutical treatments, and with fewer side effects.
Precision engineering in BCI systems
With modern BCIs, it is not just outcomes that are remarkable, but also the means by which they are achieved. Given the delicacy of this interface, the fragility of brain tissue, and the sensitivity of the hardware, precise engineering is vital.
Advanced BCIs use ultra-fine electrodes that are thinner than a human hair, which sit on the surface of the brain or are implanted into brain tissue. Micro-electrode arrays pick up electrical activity with acute precision, tracking the firing of individual neurons. In some systems, these signals are transmitted wirelessly to an external device, where machine learning algorithms convert them into actionable data.
These ultra‑fine wires demand not only precision but also deep technical know‑how to ensure perfect calibration. Alleima offers OEMs a full-service partnership that spans material selection, from stainless steel and cobalt‑chromium alloys to noble metals such as platinum‑iridium and gold. Exacting dimension control down to 0.007mm, Alleima also provide advanced surface treatments, such as polymer or electroplated finishes, for insulation, conductance, and biocompatibility.
Their one-stop approach and agile development process not only minimises variability but also accelerates time‑to‑market through collaboration in design and prototyping. Its customised processes span precision processing of ultra-fine medical wire and nitinol, laser technologies, and capabilities in precision microwire probes. With decades of experience in solutions that sense, transmit, measure, stimulate, catch or cut, Alleima equips OEMs with calibrated, high‑quality wire-based solutions tailored to complex, life-changing applications in neurostimulation and beyond. To find out more about how Alleima can support the development of your BCI system, visit their .
