3D Printed Flexible Strain Sensors: From Printing to Devices and Signals

Engineering robust and transparent dual-crosslinked hydrogels for multimodal sensing without conductive additives

Conductive hydrogels are pivotal for the advancement of flexible sensors, electronic skin, and healthcare monitoring systems, facilitating transformative innovations. However, issues such as inadequate intrinsic compatibility, mismatched mechanical properties, and limited stability curtail their potential, resulting in compromised device efficacy and performance degradation. In this research, we engineered functional hydrogels featuring a dual-crosslinked network composed of (PA/PVA)-P(AM-AA) to address these challenges. This design eliminates the need for conductive additives, thereby enhancing intrinsic compatibility. Notably, the hydrogels exhibit exceptional mechanical properties, with high tensile strength (∼700 %), Young's modulus (∼5.33 MPa), increased strength (∼2.46 MPa) and toughness (∼6.59 MJ m-3). They also achieve a compressive strength of ∼7.33 MPa at 80 % maximal compressive strain and maintain about 89 % transparency. Moreover, flexible sensors derived from these hydrogels demonstrate enhanced multimodal sensing capabilities, including temperature, strain, and pressure detection, enabling precise monitoring of human movements. The integration of multiple hydrogels into a three-dimensional sensor array facilitates detailed spatial pressure distribution mapping. By strategically applying dual-crosslinked network engineering and eliminating conductive additives, we have streamlined the design and manufacturing of hydrogels to meet the rising demand for high-performance wearable sensors.

Flexible Graphene Field-Effect Transistors and Their Application in Flexible Biomedical Sensing

Flexible electronics are transforming our lives by making daily activities more convenient. Central to this innovation are field-effect transistors (FETs), valued for their efficient signal processing, nanoscale fabrication, low-power consumption, fast response times, and versatility. Graphene, known for its exceptional mechanical properties, high electron mobility, and biocompatibility, is an ideal material for FET channels and sensors. The combination of graphene and FETs has given rise to flexible graphene field-effect transistors (FGFETs), driving significant advances in flexible electronics and sparked a strong interest in flexible biomedical sensors. Here, we first provide a brief overview of the basic structure, operating mechanism, and evaluation parameters of FGFETs, and delve into their material selection and patterning techniques. The ability of FGFETs to sense strains and biomolecular charges opens up diverse application possibilities. We specifically analyze the latest strategies for integrating FGFETs into wearable and implantable flexible biomedical sensors, focusing on the key aspects of constructing high-quality flexible biomedical sensors. Finally, we discuss the current challenges and prospects of FGFETs and their applications in biomedical sensors. This review will provide valuable insights and inspiration for ongoing research to improve the quality of FGFETs and broaden their application prospects in flexible biomedical sensing.

Advancements in Flexible Electronics Fabrication: Film Formation, Patterning, and Interface Optimization for Cutting-Edge Healthcare Monitoring Devices

Flexible electronics can seamlessly adhere to human skin or internal tissues, enabling the collection of physiological data and real-time vital sign monitoring in home settings, which give it the potential to revolutionize chronic disease management and mitigate mortality rates associated with sudden illnesses, thereby transforming current medical practices. However, the development of flexible electronic devices still faces several challenges, including issues pertaining to material selection, limited functionality, and performance instability. Among these challenges, the choice of appropriate materials, as well as their methods for film formation and patterning, lays the groundwork for versatile device development. Establishing stable interfaces, both internally within the device and in human-machine interactions, is essential for ensuring efficient, accurate, and long-term monitoring in health electronics. This review aims to provide an overview of critical fabrication steps and interface optimization strategies in the realm of flexible health electronics. Specifically, we discuss common thin film processing methods, patterning techniques for functional layers, interface challenges, and potential adjustment strategies. The objective is to synthesize recent advancements and serve as a reference for the development of innovative flexible health monitoring devices.

Self-powered strain sensing devices with wireless transmission: DIW-printed conductive hydrogel electrodes featuring stretchable and self-healing properties

With rapid advancements in health and human-computer interaction, wearable electronic skins (e-skins) designed for application on the human body provide a platform for real-time detection of physiological signals. Wearable strain sensors, integral functional units within e-skins, can be integrated with Internet of Things (IoT) technology to broaden the applications for human body monitoring. A significant challenge lies in the reliance of most existing wearable strain sensors on rigid external power supplies, limiting their practical flexibility. In this study, we present an innovative strategy to fabricate glutaraldehyde (GA)-poly(vinyl alcohol) (PVA)/cellulose nanocrystals (CNC)/Poly(3,4-ethylenedioxythiophene):poly(styrene sulfonate) (PEDOT:PSS) conductive hydrogels through multiple hydrogen bonding systems. Combining the advantageous rheological properties of the precursor solution and the high specific surface area after freeze-thaw cycling, we have created a self-powered sensing system prepared by large-area printing using direct ink writing (DIW) printing. The resulting conductive hydrogel exhibits commendable mechanical properties (411 KPa), impressive stretchability (580 %), and robust self-healing capabilities (>98.3 %). The strain sensor, derived from the conductive hydrogel, demonstrates a gauge factor (GF) of 2.5 within a stretching range of 0-580 %. Additionally, the resultant supercapacitor displays a peak energy density of 0.131 mWh/cm3 at a power density of 3.6 mW/cm3. Benefiting from its elevated strain response and remarkable power density features, this self-powered strain sensing system enables the real-time monitoring of human joint motion. The incorporation of a 5G transmission module enhances its capabilities for remote data monitoring, thereby contributing to the progress of wireless tracking technologies for self-powered electronic skin.

A Highly Sensitive and Stretchable Core-Shell Fiber Sensor for Gesture Recognition and Surface Pressure Distribution Monitoring

This work reports a highly-strain flexible fiber sensor with a core-shell structure utilizes a unique swelling diffusion technique to infiltrate carbon nanotubes (CNTs) into the surface layer of Ecoflex fibers. Compared with traditional blended Ecoflex/CNTs fibers, this manufacturing process ensures that the sensor maintains the mechanical properties (923% strain) of the Ecoflex fiber while also improving sensitivity (gauge factor is up to 3716). By adjusting the penetration time during fabrication, the sensor can be customized for different uses. As an application demonstration, the fiber sensor is integrated into the glove to develop a wearable gesture language recognition system with high sensitivity and precision. Additionally, the authors successfully monitor the pressure distribution on the curved surface of a soccer ball by winding the fiber sensor along the ball's surface.

Volume-Metallization 3D-Printed Polymer Composites

3D printing polymer or metal can achieve complicated structures while lacking multifunctional performance. Combined printing of polymer and metal is desirable and challenging due to their insurmountable mismatch in melting-point temperatures. Here, a novel volume-metallization 3D-printed polymer composite (VMPC) with bicontinuous phases for enabling coupled structure and function, which are prepared by infilling low-melting-point metal (LM) to controllable porous configuration is reported. Based on vacuum-assisted low-pressure conditions, LM is guided by atmospheric pressure action and overcomes surface tension to spread along the printed polymer pore channel, enabling the complete filling saturation of porous structures for enhanced tensile strength (up to 35.41 MPa), thermal (up to 25.29 Wm-1K-1) and electrical (>106 S m-1) conductivities. The designed 3D-printed microstructure-oriented can achieve synergistic anisotropy in mechanics (1.67), thermal (27.2), and electrical (>1012) conductivities. VMPC multifunction is demonstrated, including customized 3D electronics with elevated strength, electromagnetic wave-guided transport and signal amplification, heat dissipation device for chip temperature control, and storage components for thermoelectric generator energy conversion with light-heat-electricity.

Additively Manufactured Flexible Liquid Metal-Coated Self-Powered Magnetoelectric Sensors with High Design Freedom

Although additive manufacturing enables controllable structural design and customized performance for magnetoelectric sensors, their design and fabrication still require careful matching of the size and modulus between the magnetic and conductive components. Achieving magnetoelectric integration remains challenging, and the rigid coils limit the flexibility of the sensors. To overcome these obstacles, this study proposes a composite process combining selective laser sintering (SLS) and 3D transfer printing for fabricating flexible liquid metal-coated magnetoelectric sensors. The liquid metal forms a conformal conductive network on the SLS-printed magnetic lattice structure. Deformation of the structure alters the magnetic flux passing through it, thereby generating voltage. A reverse model segmentation and summation method is established to calculate the theoretical magnetic flux. The impact of the volume fraction, unit size, and height of the sensors on the voltage is studied, and optimization of these factors yields a maximum voltage of 45.6 µV. The sensor has excellent sensing performance with a sensitivity of 10.9 kPa-1 and a minimum detection pressure of 0.1 kPa. The voltage can be generated through various external forces. This work presents a significant advancement in fabricating liquid metal-based magnetoelectric sensors by improving their structural flexibility, magnetoelectric integration, and design freedom.

Recent Advances in the 3D Printing of Conductive Hydrogels for Sensor Applications: A Review

Conductive hydrogels, known for their flexibility, biocompatibility, and conductivity, have found extensive applications in fields such as healthcare, environmental monitoring, and soft robotics. Recent advancements in 3D printing technologies have transformed the fabrication of conductive hydrogels, creating new opportunities for sensing applications. This review provides a comprehensive overview of the advancements in the fabrication and application of 3D-printed conductive hydrogel sensors. First, the basic principles and fabrication techniques of conductive hydrogels are briefly reviewed. We then explore various 3D printing methods for conductive hydrogels, discussing their respective strengths and limitations. The review also summarizes the applications of 3D-printed conductive hydrogel-based sensors. In addition, perspectives on 3D-printed conductive hydrogel sensors are highlighted. This review aims to equip researchers and engineers with insights into the current landscape of 3D-printed conductive hydrogel sensors and to inspire future innovations in this promising field.

Combinatorial Bionic Hierarchical Flexible Strain Sensor for Sign Language Recognition with Machine Learning

Flexible strain sensors have been widely researched in fields such as smart wearables, human health monitoring, and biomedical applications. However, achieving a wide sensing range and high sensitivity of flexible strain sensors simultaneously remains a challenge, limiting their further applications. To address these issues, a cross-scale combinatorial bionic hierarchical design featuring microscale morphology combined with a macroscale base to balance the sensing range and sensitivity is presented. Inspired by the combination of serpentine and butterfly wing structures, this study employs three-dimensional printing, prestretching, and mold transfer processes to construct a combinatorial bionic hierarchical flexible strain sensor (CBH-sensor) with serpentine-shaped inverted-V-groove/wrinkling-cracking structures. The CBH-sensor has a high wide sensing range of 150% and high sensitivity with a gauge factor of up to 2416.67. In addition, it demonstrates the application of the CBH-sensor array in sign language gesture recognition, successfully identifying nine different sign language gestures with an impressive accuracy of 100% with the assistance of machine learning. The CBH-sensor exhibits considerable promise for use in enabling unobstructed communication between individuals who use sign language and those who do not. Furthermore, it has wide-ranging possibilities for use in the field of gesture-driven interactions in human-computer interfaces.

Additive Manufacturing Provides Infinite Possibilities for Self-Sensing Technology

Integrating sensors and other functional parts in one device can enable a new generation of integrated intelligent devices that can perform self-sensing and monitoring autonomously. Applications include buildings that detect and repair damage, robots that monitor conditions and perform real-time correction and reconstruction, aircraft capable of real-time perception of the internal and external environment, and medical devices and prosthetics with a realistic sense of touch. Although integrating sensors and other functional parts into self-sensing intelligent devices has become increasingly common, additive manufacturing has only been marginally explored. This review focuses on additive manufacturing integrated design, printing equipment, and printable materials and stuctures. The importance of the material, structure, and function of integrated manufacturing are highlighted. The study summarizes current challenges to be addressed and provides suggestions for future development directions.

An Extensive Study of the Influence of Key Flow Variables on Printed Line Quality Outcomes during Aerosol Jet Printing Using Coupled Three-Dimensional Numerical Models

A three-dimensional (3D) numerical model was developed to explore the intricate aerodynamic mechanisms associated with aerosol jet printing (AJP). The proposed approach integrates computational fluid dynamics and discrete phase modeling, offering a comprehensive understanding of the deposition mechanisms of the AJP process. Initially, numerical solutions of the governing equations were obtained under the assumptions of compressible and laminar flows, facilitating an analysis of certain key flow variables, in this case, the sheath gas flow rate and carrier gas flow rate across the fluid domain. Subsequently, incorporating a Lagrangian discrete phase model allowed a detailed examination of the droplet behavior after nozzle ejection, considering the influence of the Saffman lift force. Finally, experiments were performed to elucidate the influence of key flow variables on the printed width. Generally, the measured printed line morphology and corresponding line electrical performance exhibited close conformity with the numerical model, demonstrating that the proposed numerical model is important for making well-informed decisions during process optimization.

Skin-inspired, sensory robots for electronic implants

Drawing inspiration from cohesive integration of skeletal muscles and sensory skins in vertebrate animals, we present a design strategy of soft robots, primarily consisting of an electronic skin (e-skin) and an artificial muscle. These robots integrate multifunctional sensing and on-demand actuation into a biocompatible platform using an in-situ solution-based method. They feature biomimetic designs that enable adaptive motions and stress-free contact with tissues, supported by a battery-free wireless module for untethered operation. Demonstrations range from a robotic cuff for detecting blood pressure, to a robotic gripper for tracking bladder volume, an ingestible robot for pH sensing and on-site drug delivery, and a robotic patch for quantifying cardiac function and delivering electrotherapy, highlighting the application versatilities and potentials of the bio-inspired soft robots. Our designs establish a universal strategy with a broad range of sensing and responsive materials, to form integrated soft robots for medical technology and beyond.

Research on high sensitivity piezoresistive sensor based on structural design

With the popularity of smart terminals, wearable electronic devices have shown great market prospects, especially high-sensitivity pressure sensors, which can monitor micro-stimuli and high-precision dynamic external stimuli, and will have an important impact on future functional development. Compressible flexible sensors have attracted wide attention due to their simple sensing mechanism and the advantages of light weight and convenience. Sensors with high sensitivity are very sensitive to pressure and can detect resistance/current changes under pressure, which has been widely studied. On this basis, this review focuses on analyzing the performance impact of device structure design strategies on high sensitivity pressure sensors. The design of structures can be divided into interface microstructures and three-dimensional framework structures. The preparation methods of various structures are introduced in detail, and the current research status and future development challenges are summarized.

3D Printing Self-Healing and Self-Adhesive Elastomers for Wearable Electronics in Amphibious Environments

To meet the demands of challenging usage scenarios, there is an increasing need for flexible electronic skins that can operate properly not only in terrestrial environments but also extend to complex aquatic conditions. In this study, we develop an elastomer by incorporating dynamic urea bonds and hydrogen bonds into the polydimethylsiloxane backbone, which exhibits excellent autonomous self-healing and reversible adhesive performance in both dry and wet environments. A multifunctional flexible sensor with excellent sensing stability, amphibious self-healing capacity, and amphibious self-adhesive performance is fabricated through solvent-free 3D printing. The sensor has a high sensing sensitivity (GF = 45.1) and a low strain response threshold (0.25%) and can be used to detect small human movements and physiological activities, such as muscle movement, joint movement, respiration, and heartbeat. The wireless wearable sensing system assembled by coupling this device with a bluetooth transmission system is suitable for monitoring strenuous human movement in amphibious environments, such as playing basketball, cycling, running (terrestrial environments), and swimming (aquatic environments). The design strategy provides insights into enhancing the self-healing and self-adhesive properties of soft materials and promises a prospective avenue for fabricating flexible electronic skin that can work properly in amphibious environments.

Design of a Wearable Real-Time Hand Motion Tracking System Using an Array of Soft Polymer Acoustic Waveguides

Robust hand motion tracking holds promise for improved human-machine interaction in diverse fields, including virtual reality, and automated sign language translation. However, current wearable hand motion tracking approaches are typically limited in detection performance, wearability, and durability. This article presents a hand motion tracking system using multiple soft polymer acoustic waveguides (SPAWs). The innovative use of SPAWs as strain sensors offers several advantages that address the limitations. SPAWs are easily manufactured by casting a soft polymer shaped as a soft acoustic waveguide and containing a commercially available small ceramic piezoelectric transducer. When used as strain sensors, SPAWs demonstrate high stretchability (up to 100%), high linearity (R2 > 0.996 in all quasi-static, dynamic, and durability tensile tests), negligible hysteresis (<0.7410% under strain of up to 100%), excellent repeatability, and outstanding durability (up to 100,000 cycles). SPAWs also show high accuracy for continuous finger angle estimation (average root-mean-square errors [RMSE] <2.00°) at various flexion-extension speeds. Finally, a hand-tracking system is designed based on a SPAW array. An example application is developed to demonstrate the performance of SPAWs in real-time hand motion tracking in a three-dimensional (3D) virtual environment. To our knowledge, the system detailed in this article is the first to use soft acoustic waveguides to capture human motion. This work is part of an ongoing effort to develop soft sensors using both time and frequency domains, with the goal of extracting decoupled signals from simple sensing structures. As such, it represents a novel and promising path toward soft, simple, and wearable multimodal sensors.

Additive Manufacturing of Stretchable Multi-Walled Carbon Nanotubes/Thermoplastic Polyurethanes Conducting Polymers for Strain Sensing

With the development of science and technology, flexible sensors play an indispensable role in body monitoring. Rapid prototyping of high-performance flexible sensors has become an important method to develop flexible sensors. The purpose of this study was to develop a flexible resin with multi-walled carbon nanotubes (MWCNTs) for the rapid fabrication of flexible sensors using digital light processing additive manufacturing. In this study, MWCNTs were mixed in thermoplastic polyurethane (TPU) photosensitive resin to prepare polymer-matrix composites, and a flexible strain sensor was prepared using self-developed additive equipment. The results showed that the 1.2 wt% MWCNTs/TPU composite flexible sensor had high gauge factor of 9.988 with a linearity up to 45% strain and high mechanical durability (1000 cycles). Furthermore, the sensor could be used for gesture recognition and monitoring and has good performance. This method is expected to provide a new idea for the rapid personalized forming of flexible sensors.

Wafer-Recyclable, Eco-Friendly, and Multiscale Dry Transfer Printing by Transferable Photoresist for Flexible Epidermal Electronics

Flexible electronics have been of great interest in the past few decades for their wide-ranging applications in health monitoring, human-machine interaction, artificial intelligence, and biomedical engineering. Currently, transfer printing is a popular technology for flexible electronics manufacturing. However, typical sacrificial intermediate layer-based transfer printing through chemical reactions results in a series of challenges, such as time consumption and interface incompatibility. In this paper, we have developed a time-saving, wafer-recyclable, eco-friendly, and multiscale transfer printing method by using a stable transferable photoresist. Demonstration of photoresist with various, high-resolution, and multiscale patterns from the donor substrate of silicon wafer to different flexible polymer substrates without any damage is conducted using the as-developed dry transfer printing process. Notably, by utilizing the photoresist patterns as conformal masks and combining them with physical vapor deposition and dry lift-off processes, we have achieved in situ fabrication of metal patterns on flexible substrates. Furthermore, a mechanical experiment has been conducted to demonstrate the mechanism of photoresist transfer printing and dry lift-off processes. Finally, we demonstrated the application of in situ fabricated electrode devices for collecting electromyography and electrocardiogram signals. Compared to commercially available hydrogel electrodes, our electrodes exhibited higher sensitivity, greater stability, and the ability to achieve long-term health monitoring.

New Carbon Materials for Multifunctional Soft Electronics

Soft electronics are garnering significant attention due to their wide-ranging applications in artificial skin, health monitoring, human-machine interaction, artificial intelligence, and the Internet of Things. Various soft physical sensors such as mechanical sensors, temperature sensors, and humidity sensors are the fundamental building blocks for soft electronics. While the fast growth and widespread utilization of electronic devices have elevated life quality, the consequential electromagnetic interference (EMI) and radiation pose potential threats to device precision and human health. Another substantial concern pertains to overheating issues that occur during prolonged operation. Therefore, the design of multifunctional soft electronics exhibiting excellent capabilities in sensing, EMI shielding, and thermal management is of paramount importance. Because of the prominent advantages in chemical stability, electrical and thermal conductivity, and easy functionalization, new carbon materials including carbon nanotubes, graphene and its derivatives, graphdiyne, and sustainable natural-biomass-derived carbon are particularly promising candidates for multifunctional soft electronics. This review summarizes the latest advancements in multifunctional soft electronics based on new carbon materials across a range of performance aspects, mainly focusing on the structure or composite design, and fabrication method on the physical signals monitoring, EMI shielding, and thermal management. Furthermore, the device integration strategies and corresponding intriguing applications are highlighted. Finally, this review presents prospects aimed at overcoming current barriers and advancing the development of state-of-the-art multifunctional soft electronics.

Three-Dimensional Printing of Hydrogels for Flexible Sensors: A Review

The remarkable flexibility and heightened sensitivity of flexible sensors have drawn significant attention, setting them apart from traditional sensor technology. Within this domain, hydrogels-3D crosslinked networks of hydrophilic polymers-emerge as a leading material for the new generation of flexible sensors, thanks to their unique material properties. These include structural versatility, which imparts traits like adhesiveness and self-healing capabilities. Traditional templating-based methods fall short of tailor-made applications in crafting flexible sensors. In contrast, 3D printing technology stands out with its superior fabrication precision, cost-effectiveness, and satisfactory production efficiency, making it a more suitable approach than templating-based strategies. This review spotlights the latest hydrogel-based flexible sensors developed through 3D printing. It begins by categorizing hydrogels and outlining various 3D-printing techniques. It then focuses on a range of flexible sensors-including those for strain, pressure, pH, temperature, and biosensors-detailing their fabrication methods and applications. Furthermore, it explores the sensing mechanisms and concludes with an analysis of existing challenges and prospects for future research breakthroughs in this field.

Solid-state, liquid-free ion-conducting elastomers: rising-star platforms for flexible intelligent devices

Soft ionic conductors have emerged as a powerful toolkit to engineer transparent flexible intelligent devices that go beyond their conventional counterparts. Particularly, due to their superior capacities of eliminating the evaporation, freezing and leakage issues of the liquid phase encountered with hydrogels, organohydrogels and ionogels, the emerging solid-state, liquid-free ion-conducting elastomers have been largely recognized as ideal candidates for intelligent flexible devices. However, despite their extensive development, a comprehensive and timely review in this emerging field is lacking, particularly from the perspective of design principles, advanced manufacturing, and distinctive applications. Herein, we present (1) the design principles and intriguing merits of solid-state, liquid-free ion-conducting elastomers; (2) the methods to manufacture solid-state, liquid-free ion-conducting elastomers with preferential architectures and functions using advanced technologies such as 3D printing; (3) how to leverage solid-state, liquid-free ion-conducting elastomers in exploiting advanced applications, especially in the fields of flexible wearable sensors, bioelectronics and energy harvesting; (4) what are the unsolved scientific and technical challenges and future opportunities in this multidisciplinary field. We envision that this review will provide a paradigm shift to trigger insightful thinking and innovation in the development of intelligent flexible devices and beyond.

Stretchable Electronics with Strain-Resistive Performance

Stretchable electronics have attracted tremendous attention amongst academic and industrial communities due to their prospective applications in personal healthcare, human-activity monitoring, artificial skins, wearable displays, human-machine interfaces, etc. Other than mechanical robustness, stable performances under complex strains in these devices that are not for strain sensing are equally important for practical applications. Here, a comprehensive summarization of recent advances in stretchable electronics with strain-resistive performance is presented. First, detailed overviews of intrinsically strain-resistive stretchable materials, including conductors, semiconductors, and insulators, are given. Then, systematic representations of advanced structures, including helical, serpentine, meshy, wrinkled, and kirigami-based structures, for strain-resistive performance are summarized. Next, stretchable arrays and circuits with strain-resistive performance, that integrate multiple functionalities and enable complex behaviors, are introduced. This review presents a detailed overview of recent progress in stretchable electronics with strain-resistive performances and provides a guideline for the future development of stretchable electronics.

Exploring the Potentials of Chitin and Chitosan-Based Bioinks for 3D-Printing of Flexible Electronics: The Future of Sustainable Bioelectronics

Chitin and chitosan-based bioink for 3D-printed flexible electronics have tremendous potential for innovation in healthcare, agriculture, the environment, and industry. This biomaterial is suitable for 3D printing because it is highly stretchable, super-flexible, affordable, ultrathin, and lightweight. Owing to its ease of use, on-demand manufacturing, accurate and regulated deposition, and versatility with flexible and soft functional materials, 3D printing has revolutionized free-form construction and end-user customization. This study examined the potential of employing chitin and chitosan-based bioinks to build 3D-printed flexible electronic devices and optimize bioink formulation, printing parameters, and postprocessing processes to improve mechanical and electrical properties. The exploration of 3D-printed chitin and chitosan-based flexible bioelectronics will open new avenues for new flexible materials for numerous industrial applications.

Computational design of ultra-robust strain sensors for soft robot perception and autonomy

Compliant strain sensors are crucial for soft robots' perception and autonomy. However, their deformable bodies and dynamic actuation pose challenges in predictive sensor manufacturing and long-term robustness. This necessitates accurate sensor modelling and well-controlled sensor structural changes under strain. Here, we present a computational sensor design featuring a programmed crack array within micro-crumples strategy. By controlling the user-defined structure, the sensing performance becomes highly tunable and can be accurately modelled by physical models. Moreover, they maintain robust responsiveness under various demanding conditions including noise interruptions (50% strain), intermittent cyclic loadings (100,000 cycles), and dynamic frequencies (0-23 Hz), satisfying soft robots of diverse scaling from macro to micro. Finally, machine intelligence is applied to a sensor-integrated origami robot, enabling robotic trajectory prediction (<4% error) and topographical altitude awareness (<10% error). This strategy holds promise for advancing soft robotic capabilities in exploration, rescue operations, and swarming behaviors in complex environments.

Mechanically Durable Superhydrophobic Strain Sensors with High Biocompatibility and Sensing Performance for Underwater Motion Monitoring

Much progress has been made toward the development of wearable flexible strain sensors with high sensing performance to monitor human motion, but continuous function in harsh aqueous environments remains a significant challenge. A promising strategy has been the design of sensors with highly durable superhydrophobicity and maintenance of unique sensing properties. Herein, an extremely durable superhydrophobic strain sensor with an ultrawide sensing range was simply fabricated by directly brushing conductive carbon black nanoparticles (CBNPs) onto an elastic silicone rubber sheet (SS) with poly(dimethylsiloxane) (PDMS) coatings (i.e., SS/PDMS-CBNPs sensors). First, this method avoided the use of toxic solvents and a conventional prestretching treatment. Second, considering the easily destroyed rough structures and surface chemistry for conventional superhydrophobic sensors during practical applications, the prepared SS/PDMS-CBNP sensors showed excellent mechanical durability of both superhydrophobicity and sensing as examined by harsh abrasion (300 cycles), stretching (up to 200%), and ultrasonication (40 min) treatments. Third, the prepared superhydrophobic strain sensor exhibited high sensitivity (gauge factor of 101.75), high stretchability (0.015-460%), low hysteresis (83 ms), and long-term stability (10000 cycles). Fourth, the high biocompatibility of the SS/PDMS-CBNP sensor was demonstrated by rabbit skin irritation tests. Finally, the remarkable water-repellent and sensing properties of the SS/PDMS-CBNP sensor allowed its application to monitor a swimmer's real-time situation and send distress signals when needed.

Fibrous Conductive Metallogels with Hybrid Electron/Ion Networks for Boosted Extreme Sensitivity and High Linearity Strain Sensor

Fibrous strain sensing materials with both high sensitivity and high linearity are of significant importance for wearable sensors, yet they still face great challenges. Herein, a photo-spun reaction encapsulation strategy is proposed for the continuous fabrication of fibrous strain sensor materials (AMGF) with a core-sheath structure. Metallogels (MOGs) formed by bacterial cellulose (BC) nanofibers and Ag nanoparticles (AgNPs), and thermoplastic elastomers (TPE) are employed as the core and sheath, respectively. The in situ ultraviolet light reduction of Ag+ ensured AgNPs to maintain the interconnections between the BC nanofibers and form electron conductive networks (0.31 S m-1 ). Under applied strain, the BC nanofibers experience separation, bringing AMGF a high sensitivity (gauge factor 4.36). The concentration of free ions in the MOGs uniformly varies with applied deformation, endowing AMGF with high linearity and a goodness-of-fit of 0.98. The sheath TPE provided AMGF sensor with stable working life (>10 000 s). Furthermore, the AMGF sensors are demonstrated to monitor complex deformations of the dummy joints in real-time as a wearable sensor. Therefore, the fibrous hybrid conductive network fibers fabricated via the photo-spun reaction encapsulation strategy provide a new route for addressing the challenge of achieving both high sensitivity and high linearity.

Recent advances in lignin-based 3D printing materials: A mini-review

With the growing global population and rapid economic development, the demand for energy and raw materials is increasing, and the supply of fossil resources as the main source of energy and raw materials has reached a critical juncture. However, our overexploitation and overconsumption of fossil resources have led to serious problems, including environmental pollution, climate change, and ecosystem destruction. In the face of these challenges, we must recognize the negative impacts of the shortage of fossil resources and actively seek sustainable alternative sources of energy and resources to protect our environment and sustainable development in the future. Three-dimensional (3D) printing, an additive manufacturing technology, has been used in many fields to manufacture complex and high-precision products. While traditional manufacturing processes typically produce large amounts of waste and emissions that are harmful to the environment, 3D printing is much more energy efficient compared to traditional manufacturing methods, which helps to lower energy costs and reduce reliance on non-renewable energy sources. The development of low-carbon and environmentally friendly 3D printing materials can help to reduce carbon emissions and environmental pollution and realize the goal of sustainable development. Lignin, as the second largest renewable green biomass resource after cellulose, has great potential for manufacturing low-carbon and environmentally friendly 3D printing materials. This review presents some recent studies on the applications of lignin and its derivatives in photo-curing 3D printing, including the preparation and performance of lignin-based photosensitive prepolymers, lignin-based reactive diluents, lignin-based photo-initiators, and lignin-based additive. This review also provides recent studies on the preparation and performance of lignin-based thermoplastic polymer for Fused Deposition Modeling (FDM) 3D printing. Finally, the future challenges and industrialization prospects of lignin-based 3D printing materials are discussed.

Recent advances in smart wearable sensors as electronic skin

Flexible and multifunctional electronic devices and soft robots inspired by human organs, such as skin, have many applications. However, the emergence of electronic skins (e-skins) or textiles in biomedical engineering has made a great revolution in a myriad of people's lives who suffer from different types of diseases and problems in which their skin and muscles lose their appropriate functions. In this review, recent advances in the sensory function of the e-skins are described. Furthermore, we have categorized them from the sensory function perspective and highlighted their advantages and limitations. The categories are tactile sensors (including capacitive, piezoresistive, piezoelectric, triboelectric, and optical), temperature, and multi-sensors. In addition, we summarized the most recent advancements in sensors and their particular features. The role of material selection and structure in sensory function and other features of the e-skins are also discussed. Finally, current challenges and future prospects of these systems towards advanced biomedical applications are elaborated.

Templated Laser-Induced-Graphene-Based Tactile Sensors Enable Wearable Health Monitoring and Texture Recognition via Deep Neural Network

Flexible tactile sensors show great potential for portable healthcare and environmental monitoring applications. However, challenges persist in scaling up the manufacturing of stable tactile sensors with real-time feedback. This work demonstrates a robust approach to fabricating templated laser-induced graphene (TLIG)-based tactile sensors via laser scribing, elastomer hot-pressing transfer, and 3D printing of the Ag electrode. With different mesh sandpapers as templates, TLIG sensors with adjustable sensing properties were achieved. The tactile sensor obtains excellent sensitivity (52260.2 kPa-1 at a range of 0-7 kPa), a broad detection range (up to 1000 kPa), a low limit of detection (65 Pa), a rapid response (response/recovery time of 12/46 ms), and excellent working stability (10000 cycles). Benefiting from TLIG's high performance and waterproofness, TLIG sensors can be used as health monitors and even in underwater scenarios. TLIG sensors can also be integrated into arrays acting as receptors of the soft robotic gripper. Furthermore, a deep neural network based on the convolutional neural network was employed for texture recognition via a soft TLIG tactile sensing array, achieving an overall classification rate of 94.51% on objects with varying surface roughness, thus offering high accuracy in real-time practical scenarios.

All-Three-Dimensionally-Printed AgPd Thick-Film Strain Gauge with a Glass-Ceramic Protective Layer for High-Temperature Applications

A high-temperature thin/thick-film strain gauge (TFSG) shows development prospects for in situ strain monitoring of hot-end components due to their small perturbations, no damage, and fast response. Direct ink writing (DIW) 3D printing is an emerging and facile approach for the rapid fabrication of TFSG. However, TFSGs prepared based on 3D printing with both high thermal stability and low temperature coefficient of resistance (TCR) over a wide temperature range remain a great challenge. Here, we report a AgPd TFSG with a glass-ceramic protective layer based on DIW. By encapsulating the AgPd sensitive layer and regulating the Pd content, the AgPd TFSG demonstrated a low TCR (191.6 ppm/°C) from 50 to 800 °C and ultrahigh stability (with a resistance drift rate of 0.14%/h at 800 °C). Meanwhile, the achieved specifications for strain detection included a strain sensing range of ±500 με, fast response time of 153 ms, gauge factor of 0.75 at 800 °C, and high durability of >8000 cyclic loading tests. The AgPd TFSG effectively monitors strain in superalloys and can be directly deposited onto cylindrical surfaces, demonstrating the scalability of the presented approach. This work provides a strategy to develop TFSGs for in situ sensing of complex curved surfaces in harsh environments.

Flexible multicolor biaxial sensor for strain direction identification based on sandwich-structured mechanoluminescent materials

Strain sensors capable of recognizing the direction of strain are crucial in applications such as robot attitude adjustment and detection of strain states in complex structures. In this study, a sandwich-structured flexible biaxial strain sensor was developed using polydimethylsiloxane as the substrate, mechanoluminescent materials as the luminescent elements, and rubber-ink as the light-blocking layer. By correlating the emitted light color with the stretching state, precise identification of the applied strain direction is achieved. Additionally, the mechanoluminescence of the sensor is collected by a photodiode, generating photocurrent that can be analyzed. This provides a solution for practical applications of sensor.

An effective DLP 3D printing strategy of high strength and toughness cellulose hydrogel towards strain sensing

Photocurable 3D printing technology has outperformed extrusion-based 3D printing technology in material adaptability, resolution, and printing rate, yet is still limited by the insecure preparation and selection of photoinitiators and thus less reported. In this work, we developed a printable hydrogel that can effectively facilitate various solid or hollow structures and even lattice structures. The chemical and physical dual-crosslinking strategy combined with cellulose nanofibers (CNF) significantly improved the strength and toughness of photocurable 3D printed hydrogels. In this study, the tensile breaking strength, Young's modulus, and toughness of poly(acrylamide-co-acrylic acid)_D/cellulose nanofiber (PAM-co-PAA)_D/CNF hydrogels were 375 %, 203 % and 544 % higher than those of the traditional single chemical crosslinked (PAM-co-PAA)_S hydrogels, respectively. Notably, its outstanding compressive elasticity enabled it to recover under 90 % strain compression (about 4.12 MPa). Resultantly, the proposed hydrogel can be utilized as a flexible strain sensor to monitor the motions of human movements, such as the bending of fingers, wrists, and arms, and even the vibration of a speaking throat. The output of electrical signals can still be collected through strain even under the condition of energy shortage. In addition, photocurable 3D printing technology can provide customized services for hydrogel-based e-skin, such as hydrogel-based bracelets, fingerstall, and finger joint sleeves.

3D Printed Graphene and Graphene/Polymer Composites for Multifunctional Applications

Three-dimensional (3D) printing, alternatively known as additive manufacturing, is a transformative technology enabling precise, customized, and efficient manufacturing of components with complex structures. It revolutionizes traditional processes, allowing rapid prototyping, cost-effective production, and intricate designs. The 3D printed graphene-based materials combine graphene's exceptional properties with additive manufacturing's versatility, offering precise control over intricate structures with enhanced functionalities. To gain comprehensive insights into the development of 3D printed graphene and graphene/polymer composites, this review delves into their intricate fabrication methods, unique structural attributes, and multifaceted applications across various domains. Recent advances in printable materials, apparatus characteristics, and printed structures of typical 3D printing techniques for graphene and graphene/polymer composites are addressed, including extrusion methods (direct ink writing and fused deposition modeling), photopolymerization strategies (stereolithography and digital light processing) and powder-based techniques. Multifunctional applications in energy storage, physical sensor, stretchable conductor, electromagnetic interference shielding and wave absorption, as well as bio-applications are highlighted. Despite significant advancements in 3D printed graphene and its polymer composites, innovative studies are still necessary to fully unlock their inherent capabilities.

Polyelectrolyte elastomer-based ionotronic sensors with multi-mode sensing capabilities via multi-material 3D printing

Stretchable ionotronics have drawn increasing attention during the past decade, enabling myriad applications in engineering and biomedicine. However, existing ionotronic sensors suffer from limited sensing capabilities due to simple device structures and poor stability due to the leakage of ingredients. In this study, we rationally design and fabricate a plethora of architected leakage-free ionotronic sensors with multi-mode sensing capabilities, using DLP-based 3D printing and a polyelectrolyte elastomer. We synthesize a photo-polymerizable ionic monomer for the polyelectrolyte elastomer, which is stretchable, transparent, ionically conductive, thermally stable, and leakage-resistant. The printed sensors possess robust interfaces and extraordinary long-term stability. The multi-material 3D printing allows high flexibility in structural design, enabling the sensing of tension, compression, shear, and torsion, with on-demand tailorable sensitivities through elaborate programming of device architectures. Furthermore, we fabricate integrated ionotronic sensors that can perceive different mechanical stimuli simultaneously without mutual signal interferences. We demonstrate a sensing kit consisting of four shear sensors and one compressive sensor, and connect it to a remote-control system that is programmed to wirelessly control the flight of a drone. Multi-material 3D printing of leakage-free polyelectrolyte elastomers paves new avenues for manufacturing stretchable ionotronics by resolving the deficiencies of stability and functionalities simultaneously.

Deformation Rate-Adaptive Conducting Polymers and Composites

Materials are more easily damaged during accidents that involve rapid deformation. Here, a design strategy is described for electronic materials comprised of conducting polymers that defies this orthodox property, making their extensibility and toughness dynamically adaptive to deformation rates. This counterintuitive property is achieved through a morphology of interconnected nanoscopic core-shell micelles, where the chemical interactions are stronger within the shells than the cores. As a result, the interlinked shells retain material integrity under strain, while the rate of dissociation of the cores controls the extent of micelle elongation, which is a process that adapts to deformation rates. A prototype based on polyaniline shows a 7.5-fold increase in ultimate elongation and a 163-fold increase in toughness when deformed at increasing rates from 2.5 to 10 000% min-1 . This concept can be generalized to other conducting polymers and highly conductive composites to create "self-protective" soft electronic materials with enhanced durability under dynamic movement or deformation.

Electrical Resistivity of 3D-Printed Polymer Elements

During this study, the resistivity of electrically conductive structures 3D-printed via fused filament fabrication (FFF) was investigated. Electrical resistivity characterisation was performed on various structural levels of the whole 3D-printed body, starting from the single traxel (3D-printed single track element), continuing with monolayer and multilayer formation, finalising with hybrid structures of a basic nonconductive polymer and an electrically conductive one. Two commercial conductive materials were studied: Proto-Pasta and Koltron G1. It was determined that the geometry and resistivity of a single traxel influenced the resistivity of all subsequent structural elements of the printed body and affected its electrical anisotropy. In addition, the results showed that thermal postprocessing (annealing) affected the resistivity of a standalone extruded fibre (extruded filament through a printer nozzle in freefall) and traxel. The effect of Joule heating and piezoresistive properties of hybrid structures with imprinted conductive elements made from Koltron G1 were investigated. Results revealed good thermal stability within 70 °C and considerable piezoresistive response with a gauge factor of 15-25 at both low 0.1% and medium 1.5% elongations, indicating the potential of such structures for use as a heat element and strain gauge sensor in applications involving stiff materials and low elongations.

Zwitterionic Eutectogel-Based Wearable Strain Sensor with Superior Stretchability, Self-Healing, Self-Adhesion, and Wide Temperature Tolerance

Ionic conductive eutectogels have great application prospects in wearable strain sensors owing to their temperature tolerance, simplicity, and low cost. Eutectogels prepared by cross-linking polymers have good tensile properties, strong self-healing capacities, and excellent surface-adaptive adhesion. Herein, we emphasize for the first time the potential of zwitterionic deep eutectic solvents (DESs), in which betaine is a hydrogen bond acceptor. Polymeric zwitterionic eutectogels were prepared by directly polymerizing acrylamide in zwitterionic DESs. The obtained eutectogels owned excellent ionic conductivity (0.23 mS cm^-1), superior stretchability (approximately 1400% elongation), self-healing (82.01%), self-adhesion, and wide temperature tolerance. Accordingly, the zwitterionic eutectogel was successfully applied in wearable self-adhesive strain sensors, which can adhere to skins and monitor body motions with high sensitivity and excellent cyclic stability over a wide temperature range (-80 to 80 °C). Moreover, this strain sensor owned an appealing sensing function on bidirectional monitoring. The findings in this work can pave the way for the design of soft materials with versatility and environmental adaptation.

A Review of Epidermal Flexible Pressure Sensing Arrays

In recent years, flexible pressure sensing arrays applied in medical monitoring, human-machine interaction, and the Internet of Things have received a lot of attention for their excellent performance. Epidermal sensing arrays can enable the sensing of physiological information, pressure, and other information such as haptics, providing new avenues for the development of wearable devices. This paper reviews the recent research progress on epidermal flexible pressure sensing arrays. Firstly, the fantastic performance materials currently used to prepare flexible pressure sensing arrays are outlined in terms of substrate layer, electrode layer, and sensitive layer. In addition, the general fabrication processes of the materials are summarized, including three-dimensional (3D) printing, screen printing, and laser engraving. Subsequently, the electrode layer structures and sensitive layer microstructures used to further improve the performance design of sensing arrays are discussed based on the limitations of the materials. Furthermore, we present recent advances in the application of fantastic-performance epidermal flexible pressure sensing arrays and their integration with back-end circuits. Finally, the potential challenges and development prospects of flexible pressure sensing arrays are discussed in a comprehensive manner.

Evolution of nanostructured skin patches towards multifunctional wearable platforms for biomedical applications

Recent advances in the field of skin patches have promoted the development of wearable and implantable bioelectronics for long-term, continuous healthcare management and targeted therapy. However, the design of electronic skin (e-skin) patches with stretchable components is still challenging and requires an in-depth understanding of the skin-attachable substrate layer, functional biomaterials and advanced self-powered electronics. In this comprehensive review, we present the evolution of skin patches from functional nanostructured materials to multi-functional and stimuli-responsive patches towards flexible substrates and emerging biomaterials for e-skin patches, including the material selection, structure design and promising applications. Stretchable sensors and self-powered e-skin patches are also discussed, ranging from electrical stimulation for clinical procedures to continuous health monitoring and integrated systems for comprehensive healthcare management. Moreover, an integrated energy harvester with bioelectronics enables the fabrication of self-powered electronic skin patches, which can effectively solve the energy supply and overcome the drawbacks induced by bulky battery-driven devices. However, to realize the full potential offered by these advancements, several challenges must be addressed for next-generation e-skin patches. Finally, future opportunities and positive outlooks are presented on the future directions of bioelectronics. It is believed that innovative material design, structure engineering, and in-depth study of fundamental principles can foster the rapid evolution of electronic skin patches, and eventually enable self-powered close-looped bioelectronic systems to benefit mankind.

3D Printed Graphene-Based Metamaterials: Guesting Multi-Functionality in One Gain

Advanced functional materials with fascinating properties and extended structural design have greatly broadened their applications. Metamaterials, exhibiting unprecedented physical properties (mechanical, electromagnetic, acoustic, etc.), are considered frontiers of physics, material science, and engineering. With the emerging 3D printing technology, the manufacturing of metamaterials becomes much more convenient. Graphene, due to its superior properties such as large surface area, superior electrical/thermal conductivity, and outstanding mechanical properties, shows promising applications to add multi-functionality into existing metamaterials for various applications. In this review, the aim is to outline the latest developments and applications of 3D printed graphene-based metamaterials. The structure design of different types of metamaterials and the fabrication strategies for 3D printed graphene-based materials are first reviewed. Then the representative explorations of 3D printed graphene-based metamaterials and multi-functionality that can be introduced with such a combination are further discussed. Subsequently, challenges and opportunities are provided, seeking to point out future directions of 3D printed graphene-based metamaterials.

Direct Ink-Write Printing of Ceramic Clay with an Embedded Wireless Temperature and Relative Humidity Sensor

This research presents a simple method to additively manufacture Cone 5 porcelain clay ceramics by using the direct ink-write (DIW) printing technique. DIW has allowed the application of extruding highly viscous ceramic materials with relatively high-quality and good mechanical properties, which additionally allows a freedom of design and the capability of manufacturing complex geometrical shapes. Clay particles were mixed with deionized (DI) water at different ratios, where the most suitable composition for 3D printing was observed at a 1:5 w/c ratio (16.2 wt.%. of DI water). Differential geometrical designs were printed to demonstrate the printing capabilities of the paste. In addition, a clay structure was fabricated with an embedded wireless temperature and relative humidity (RH) sensor during the 3D printing process. The embedded sensor read up to 65% RH and temperatures of up to 85 °F from a maximum distance of 141.7 m. The structural integrity of the selected 3D printed geometries was confirmed through the compressive strength of fired and non-fired clay samples, with strengths of 70 MPa and 90 MPa, respectively. This research demonstrates the feasibility of using the DIW printing of porcelain clay with embedded sensors, with fully functional temperature- and humidity-sensing capabilities.

Superficial and Inkjet Scalable Printed Sensors Integrated with Iron Oxide and Reduced Graphene Oxide for Sensitive Voltammetric Determination of Lurasidone

The present work demonstrated the fabrication and the electrochemical characterization of novel printed electrochemical sensors integrated with an innovative nanosensing platform based on the synergic electrocatalytic effect of iron oxide nanoparticles (FeONPs) and reduced graphene oxide (rGO) for precise voltammetric determination of the antipsychotic drug lurasidone hydrochloride (LUH). The features of the electrode surface fabricated using the ordinary inkjet printer were characterized by scanning electron microscopy and electrochemical impedance spectroscopy. Among different ink formulations, integration of the printing ink with the ratio 15 mg FeONPs and 20 mg rGO was found to be the most appropriate for sensitive quantification of LUH in biological fluids and pharmaceutical formulations in the presence of LUH degradation products. Under the optimized experimental and electroanalytical parameters, the recorded square-wave voltammograms were correlated to LUH within the linear concentration ranging from 50 to 2150 ng mL^-1 with detection limit and limit of quantification values of 15.64 and 47.39 ng mL^-1, respectively. Based on the cyclic voltammograms recorded for LUH at different scan rates, the electrode reaction was assumed to be a diffusion reaction mechanism accompanied by the transfer of two electrons/protons through the oxidation of the five-membered ring nitrogen atom as assumed by the molecular orbital calculations carried out on the LUH molecule. The C _max of LUH and the efficiency of the fabricated sensors enabled their clinical application for monitoring LUH in human biological fluids and pharmaceutical formulations in the presence of degradants for diverse quality control applications and green chemistry analysis.

Preparation of Thermoplastic Polyurethane/Multi-Walled Carbon Nanotubes Composite Foam with High Resilience Performance via Fused Filament Fabrication and CO2 Foaming Technique

Wearable flexible sensors with high sensitivity and wide detection range are applied in motion detection, medical diagnostic result and other fields, but poor resilience and hysteresis remain a challenge. In this study, a high-resilience foam sensor was prepared through a combination of additive manufacturing and green physical foaming method. The conductive filaments were prepared by using MWCNTs-modified TPU by the physical method of melt blending. Samples were prefabricated using the FFF printer and then saturated with CO2 in an autoclave before being removed and heated to foam. The composite foam effectively reduced residual strain, demonstrating the high resilience of the 3D-printed composite materials with a foam porous structure. The residual strain of the sample before foaming was >6% after a single cycle, and then gradually increased. The residual strain of the foamed samples is less than 5%. In addition, composite foam has high sensitivity and can monitor subtle pressure changes (0~40 kPa). The sensing performance of the composite foam was evaluated, and the current signal remained stable under different loading rates and small compression strains (2~5%). By using this highly resilient conductive composite material, a hierarchical shoe insole was designed that successfully detected human walking and running movements.

Cellulose Nanocrystal-Based All-3D-Printed Pyro-Piezoelectric Nanogenerator for Hybrid Energy Harvesting and Self-Powered Cardiorespiratory Monitoring toward the Human-Machine Interface

Biomaterials with spontaneous piezoelectric property are highly emerging in recent times for the generation of electricity from mechanical energy sources that are amply available in nature. In this context, pyroelectricity, an integral property of piezoelectric materials, might be an interesting tool in harvesting thermal energy from the fluctuations of temperature. On the other hand, respiration and heart pulse are the significant human vital signs that can be used for early detection and prevention of cardiorespiratory diseases. Here, we report an all-three-dimensional (3D)-printed pyro-piezoelectric nanogenerator (Py-PNG) based on the most abundant and completely biodegradable biopolymer on earth, i.e., cellulose nanocrystal (CNC) for hybrid (mechanical as well as thermal) energy harvesting, and interestingly, the NG could be used as an e-skin sensor for application in self-powered noninvasive cardiorespiratory monitoring for personal healthcare. Notably, the CNC-based device will be biocompatible and economically advantageous due to its biomaterial-based supremacy and huge availability. This is an original approach with 3D geometrical advancement in designing a NG/sensor, where the unique all-3D-printed manner is adopted, and certainly, it has promising potential in reducing the number of processing steps to required equipment during the multilayer fabrication. The all-3D-printed NG/sensor shows outstanding mechano-thermal energy harvesting performance along with sensitivity and is capable of accurate detection of heart pulse as well as respiration, whenever and whichever required without the need of any battery or an external power supply. In addition, we have also extended its application in demonstrating a smart mask-based breath monitoring system. Thus, the real-time cardiorespiratory monitoring provides notable and fascinating information in medical diagnosis, stepping toward biomedical device development and human-machine interface.

Photocurable and elastic polyurethane based on polyether glycol with adjustable hardness for 3D printing customized flatfoot orthosis

Orthopedic insoles is the most commonly used nonsurgical treatment method for the flatfoot. Polyurethane (PU) plays a crucial role in the manufacturing of orthopedic insoles due to its high wear resistance and elastic recovery. However, preparing orthopedic insoles with adjustable hardness, high-accuracy, and matches the plantar morphology is challenging. Herein, a liquid crystal display (LCD) three-dimensional (3D) printer was used to prepare the customized arch-support insoles based on photo-curable and elastic polyurethane acrylate (PUA) composite resins. Two kinds of photo-curable polyurethanes (DL1000-PUA and DL2000-PUA) were successfully synthesized, and a series of fast-photocuring polyurethane acrylate (PUA) composite resins for photo-polymerization 3D printing were developed. The effects of different acrylate monomers on the Shore hardness, viscosity, and mechanical properties of the PUA composite resins were evaluated. The PUA-3-1 composite resin exhibited low viscosity, optimal hardness, and mechanical properties. A deviation analysis was conducted to assess the accuracy of printed insole. Furthermore, the stress conditions of the PUA composite resin and ethylene vinyl acetate (EVA) under the weight load of healthy adults were compared by finite element analysis (FEA) simulation. The results demonstrated that the stress of the PUA composite resin and EVA were 0.152 MPa and 0.285 MPa, and displacement were 0.051 mm and 3.449 mm, respectively. These results indicate that 3D-printed arch-support insole based on photocurable PUA composite resin are high-accuracy, and can reduce plantar pressure and prevent insoles premature deformation, which show great potential in the physiotherapeutic intervention for foot disorders.

Additive Manufactured Strain Sensor Using Stereolithography Method with Photopolymer Material

As a result of the developments in additive manufacturing (AM) technology, 3D printing is transforming from a method used only in rapid prototyping to a technique used to produce large-scale equipment. This study presents the fabrication and experimental studies of a 3D-printed strain sensor that can be used directly in soft applications. Photopolymer-based conductive and flexible ultraviolet (UV) resin materials are used in the fabrication of the sensor. A Stereolithography (SLA)-based printer is preferred for 3D fabrication. The bottom base of the sensor, which consists of two parts, is produced from flexible UV resin, while the channels that should be conductive are produced from conductive UV resin. In total, a strain sensor with a thickness of 2 mm was produced. Experimental studies were carried out under loading and unloading conditions to observe the hysteresis effect of the sensor. The results showed a close linear relationship between the strain sensor and the measured resistance value. In addition, tensile test specimens were produced to observe the behavior of conductive and non-conductive materials. The tensile strength values obtained from the test results will provide information about the sensor placement. In addition, the flexible structure of the strain sensor will ensure its usability in many soft applications.

Direct Writing of Silver Nanowire Patterns with Line Width down to 50 μm and Ultrahigh Conductivity

Direct writing of one-dimensional nanomaterials with large aspect ratios into customized, highly conductive, and high-resolution patterns is a challenging task. In this work, thin silver nanowires (AgNWs) with a length-to-diameter ratio of 730 are employed as a representative example to demonstrate a potent direct ink writing (DIW) strategy, in which aqueous inks using a natural polymer, sodium alginate, as the thickening agent can be easily patterned with arbitrary geometries and controllable structural features on a variety of planar substrates. With the aid of a quick spray-and-dry postprinting treatment at room temperature, the electrical conductivity and substrate adhesion of the written AgNWs-patterns improve simultaneously. This simple, environment benign, and low-temperature DIW strategy is effective for depositing AgNWs into patterns that are high-resolution (with line width down to 50 μm), highly conductive (up to 1.26 × 105 S/cm), and mechanically robust and have a large alignment order of NWs, regardless of the substrate's hardness, smoothness, and hydrophilicity. Soft electroadhesion grippers utilizing as-manufactured interdigitated AgNWs-electrodes exhibit an increased shear adhesion force of up to 15.5 kPa at a driving voltage of 3 kV, indicating the strategy is very promising for the decentralized and customized manufacturing of soft electrodes for future soft electronics and robotics.

Recent Progress of Energy-Storage-Device-Integrated Sensing Systems

With the rapid prosperity of the Internet of things, intelligent human-machine interaction and health monitoring are becoming the focus of attention. Wireless sensing systems, especially self-powered sensing systems that can work continuously and sustainably for a long time without an external power supply have been successfully explored and developed. Yet, the system integrated by energy-harvester needs to be exposed to a specific energy source to drive the work, which provides limited application scenarios, low stability, and poor continuity. Integrating the energy storage unit and sensing unit into a single system may provide efficient ways to solve these above problems, promoting potential applications in portable and wearable electronics. In this review, we focus on recent advances in energy-storage-device-integrated sensing systems for wearable electronics, including tactile sensors, temperature sensors, chemical and biological sensors, and multifunctional sensing systems, because of their universal utilization in the next generation of smart personal electronics. Finally, the future perspectives of energy-storage-device-integrated sensing systems are discussed.

Droplets Patterning of Structurally Integrated 3D Conductive Networks-Based Flexible Strain Sensors for Healthcare Monitoring

Flexible strain sensors with significant extensibility, stability, and durability are essential for public healthcare due to their ability to monitor vital health signals noninvasively. However, thus far, the conductive networks have been plagued by the inconsistent interface states of the conductive components, which hampered the ultimate sensitivity performance. Here, we demonstrate structurally integrated 3D conductive networks-based flexible strain sensors of hybrid Ag nanorods/nanoparticles(AgNRs/NPs) by combining a droplet-based aerosol jet printing(AJP) process and a feasible transfer process. Structurally integrated 3D conductive networks have been intentionally developed by tweaking droplets deposition behaviors at multi-scale for efficient hybridization and ordered assembly of AgNRs/NPs. The hybrid AgNRs/NPs enhance interfacial conduction and mechanical properties during stretching. In a strain range of 25%, the developed sensor demonstrates an ideal gauge factor of 23.18. When real-time monitoring of finger bending, arm bending, squatting, and vocalization, the fabricated sensors revealed effective responses to human movements. Our findings demonstrate the efficient droplet-based AJP process is particularly capable of developing advanced flexible devices for optoelectronics and wearable electronics applications.