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Purpose: Design, fabricate and evaluate all-solid-state wearable sensor systems that can monitor ion concentrations in human sweat to provide real time health analysis and disease diagnosis capabilities. Design/methodology/approach: A human health monitoring system includes disposable customized flexible electrode array and a compact signal transmission-processing electronic unit. Findings: Patterned rGO (reduced-graphene oxide) layers can replace traditional metal electrodes for the fabrication of free-standing all solid film sensors to provide improved flexibility, sensitivity, selectivity, and stability in ion concentration monitoring. Electrochemical measurements show the open circuit potential of current selective electrodes exhibit near Nernst responses versus Na+ and K+ ion concentration in sweat. These signals show great stability during a typical measurement period of 3 weeks. Sensor performances evaluated through real time measurements on human subjects show strong correlations between subject activity and sweating levels, confirming high degree of robustness, sensitivity, reliability and practicality of current sensor systems. Originality/value: In improving flexibility, stability and interfacial coherency of chemical sensor arrays, rGO films have been the developed as a high-performance alternative to conventional electrode with significant cost and processing complexity reduction. rGO supported solid state electrode arrays have been found to have linear potential response versus ion concentration, suitable for electrochemical sensing applications. Current sweat sensor system has a high degree of integration, including electrode arrays, signal processing circuits, and data visualization interfaces. [ABSTRACT FROM AUTHOR]