Towards tunable sensitivity of electrical property to strain for conductive polymer composites based on thermoplastic elastomer

Stretchable MXene/Carbon Nanotube Bilayer Strain Sensors with Tunable Sensitivity and Working Ranges

Stretchable strain sensors have gained increasing popularity as wearable devices to convert mechanical deformation of the human body into electrical signals. Two-dimensional transition metal carbides (Ti3C2Tx MXene) are promising candidates to achieve excellent sensitivity. However, MXene films have been limited in operating strain ranges due to rapid crack propagation during stretching. In this regard, this study reports MXene/carbon nanotube bilayer films with tunable sensitivity and working ranges. The device is fabricated using a scalable process involving spray deposition of well-dispersed nanomaterial inks. The bilayer sensor's high sensitivity is attributed to the cracks that form in the MXene film, while the compliant carbon nanotube layer extends the working range by maintaining conductive pathways. Moreover, the response of the sensor is easily controlled by tuning the MXene loading, achieving a gauge factor of 9039 within 15% strain at 1.92 mg/cm2 and a gauge factor of 1443 within 108% strain at 0.55 mg/cm2. These tailored properties can precisely match the operation requirements during the wearable application, providing accurate monitoring of various body movements and physiological activities. Additionally, a smart glove with multiple integrated strain sensors is demonstrated as a human-machine interface for the real-time recognition of hand gestures based on a machine-learning algorithm. The design strategy presented here provides a convenient avenue to modulate strain sensors for targeted 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.

Highly stretchable polymer semiconductor thin films with multi-modal energy dissipation and high relative stretchability

Stretchable polymer semiconductors (PSCs) have seen great advancements alongside the development of soft electronics. But it remains a challenge to simultaneously achieve high charge carrier mobility and stretchability. Herein, we report the finding that stretchable PSC thin films (<100-nm-thick) with high stretchability tend to exhibit multi-modal energy dissipation mechanisms and have a large relative stretchability (rS) defined by the ratio of the entropic energy dissipation to the enthalpic energy dissipation under strain. They effectively recovered the original molecular ordering, as well as electrical performance, after strain was released. The highest rS value with a model polymer (P4) exhibited an average charge carrier mobility of 0.2 cm2V-1s-1 under 100% biaxial strain, while PSCs with low rS values showed irreversible morphology changes and rapid degradation of electrical performance under strain. These results suggest rS can be used as a parameter to compare the reliability and reversibility of stretchable PSC thin films.

Printed Directional Bending Sensor with High Sensitivity and Low Hysteresis for Human Motion Detection and Soft Robotic Perception

We present a high-performance flexible bending strain sensor for directional motion detection of human hands and soft robotic grippers. The sensor was fabricated using a printable porous conductive composite composed of polydimethylsiloxane (PDMS) and carbon black (CB). The utilization of a deep eutectic solvent (DES) in the ink formulation induced a phase segregation between the CB and PDMS and led to a porous structure inside the printed films after being vapored. This simple and spontaneously formed conductive architecture provided superior directional bend-sensing characteristics compared to conventional random composites. The resulting flexible bending sensors displayed high bidirectional sensitivity (gauge factor of 45.6 under compressive bending and 35.2 under tensile bending), negligible hysteresis, good linearity (>0.99), and excellent bending durability (over 10,000 cycles). The multifunctional applications of these sensors, including human motion detection, object-shape monitoring, and robotic perceptions, are demonstrated as a proof-of-concept.

Technology Roadmap for Flexible Sensors

Humans rely increasingly on sensors to address grand challenges and to improve quality of life in the era of digitalization and big data. For ubiquitous sensing, flexible sensors are developed to overcome the limitations of conventional rigid counterparts. Despite rapid advancement in bench-side research over the last decade, the market adoption of flexible sensors remains limited. To ease and to expedite their deployment, here, we identify bottlenecks hindering the maturation of flexible sensors and propose promising solutions. We first analyze challenges in achieving satisfactory sensing performance for real-world applications and then summarize issues in compatible sensor-biology interfaces, followed by brief discussions on powering and connecting sensor networks. Issues en route to commercialization and for sustainable growth of the sector are also analyzed, highlighting environmental concerns and emphasizing nontechnical issues such as business, regulatory, and ethical considerations. Additionally, we look at future intelligent flexible sensors. In proposing a comprehensive roadmap, we hope to steer research efforts towards common goals and to guide coordinated development strategies from disparate communities. Through such collaborative efforts, scientific breakthroughs can be made sooner and capitalized for the betterment of humanity.

Stretchable Strain Sensor with Small but Sufficient Adhesion to Skin

Stretchable strain sensors that use a liquid metal (eutectic gallium-indium alloy; E-GaIn) and flexible silicone rubber (Ecoflex) as the support and adhesive layers, respectively, are demonstrated. The flexibility of Ecoflex and the deformability of E-GaIn enable the sensors to be stretched by 100%. Ecoflex gel has sufficiently large adhesion force to skin, even though the adhesion force is smaller than that for commercially available adhesives. This enables the sensor to be used for non-invasive monitoring of human motion. The mechanical and electrical properties of the sensor are experimentally evaluated. The effectiveness of the proposed sensors is demonstrated by monitoring joint movements, facial expressions, and respiration.

CNT/Graphite/SBS Conductive Fibers for Strain Sensing in Wearable Telerehabilitation Devices

Rapid growth of personal electronics with concurrent research into telerehabilitation solutions discovers opportunities to redefine the future of orthopedic rehabilitation. After joint injury or operation, convalescence includes free active range of movement exercises, such as joints bending and straightening under medical supervision. Flexion detection through wearable textile sensors provides numerous potential benefits such as: (1) reduced cost; (2) continuous monitoring; (3) remote telerehabilitation; (4) gamification; and (5) detection of risk-inducing activities in daily routine. To address this issue, novel piezoresistive multi-walled carbon nanotubes/graphite/styrene–butadiene–styrene copolymer (CNT/Gr/SBS) fiber was developed. The extrusion process allowed adjustable diameter fiber production, while being a scalable, industrially adapted method of manufacturing textile electronics. Composite fibers were highly stretchable, withstanding strains up to 285%, and exhibited exceptional piezoresistive parameters with a gauge factor of 91.64 for 0–100% strain range and 2955 for the full scope. Considering the composite’s flexibility and sensitivity during a series of cyclic loading, it was concluded that developed Gr/CNT/SBS fibers were suitable for application in wearable piezoresistive sensors for telerehabilitation application.

Preparation of carbon black/silicone rubber composites with large-area-homogeneous-low electrical-resistance used as electroplating matrix

Carbon black/silicone rubber composites with large-area-homogeneous-low electrical-resistance used as electroplating matrix and its fine electro-deposited Ni layer.

Flexible and Stable Carbon Nanotube Film Strain Sensors with Self-Derived Integrated Electrodes

The development of flexible and wearable electronic devices has put an increasing demand on electrode systems with seamless connection and high compatibility with the main device, in order to accommodate complex deformation conditions and maintain stable performance. Here, we present a carbon nanotube-integrated electrode (CNTIE) by wet-pulling the ends of a carbon nanotube (CNT) film to form condensed thin fibers that resemble conventional conducting wire electrodes. A flexible strain sensor was constructed consisting of the middle CNT film as the main functional part and the CNTIE as self-derived electrodes, with inherent CNT connection between the two parts. The sensor can be transferred to versatile substrates (e.g., balloon surface) or encapsulated in thermoplastic polymers, exhibiting a large linear response range (up to 1000% in tensile strain), excellent durability and repeatability over 5000 cycles, and the ability to detect small- to large-degree human body motions. In addition, the strain sensor based on the CNTIE hybrid film (MXene/CNT and graphene/CNT) also shows superior linearity and stability at a strain range of 0-800%. Compared with the sensors using traditional silver wire electrodes and separately fabricated CNT fiber electrodes, our CNTIE plays an important role in achieving highly stable performance in the strain cycles. Our self-derived integrated electrodes provide a potential route to solve the incompatibility issues of conventional electrodes and to develop high-performance flexible and wearable systems based on CNTs and other nanomaterials.

Highly Tunable Piezoresistive Behavior of Carbon Nanotube-Containing Conductive Polymer Blend Composites Prepared from Two Polymers Exhibiting Crystallization-Induced Phase Separation

Conductive polymer composites (CPCs) are suitable as piezoresistive-sensing materials. When using CPCs for strain sensing, it is still a big challenge to simultaneously improve the piezoresistive sensitivity and linearity along with the electrical conductivity and mechanical properties. Here, highly tunable piezoresistive behavior is reported for multiwalled carbon nanotube (CNT)-filled CPCs based on blends of two semicrystalline polymers poly(vinylidene fluoride) (PVDF) and poly(butylene succinate) (PBS), which are miscible in the melt. When cooling the homogeneous mixture of the blend components, successive crystallization of PVDF and PBS occurs, creating complex crystalline structures in a mixed amorphous phase. The morphology of the blend matrix, the crystallinity of the blend components, and the dispersion and location of the CNTs in the blend depend on the CNT content and the blend composition. Compared with PVDF/CNT composites, the substitution of 10 to 50 wt % PVDF by PBS in the composites shifts the electrical percolation concentration Φ_c from 0.79 wt % to filler contents as low as 0.50 wt % while improving the stretchability. The piezoresistive behavior is highly tunable by changing the PVDF/PBS ratio. The ternary composites with matrix compositions of PVDF (90 wt %)/PBS (10 wt %) and PVDF (50 wt %)/PBS (50 wt %) show either higher piezoresistive sensitivity or linearity, respectively, caused by the differences in the microstructure of the CPCs. For example, the crystallinity of PBS in the ternary composites increased from 19.8% to 52.0% as the PBS content increased from 10 wt % to 50 wt %, which is connected with altered CNT distribution and conductive network structure and substantial improvement of the linearity of the electrical response to strains up to >20%. Our findings highly contribute to the understanding of the piezoresistive properties of CPCs based on two semicrystalline polymers and are important for future studies to tune the piezoresistive behavior to achieve simultaneously improved sensitivity and linearity.

Materials, Electrical Performance, Mechanisms, Applications, and Manufacturing Approaches for Flexible Strain Sensors

With the recent great progress made in flexible and wearable electronic materials, the upcoming next generation of skin-mountable and implantable smart devices holds extensive potential applications for the lifestyle modifying, including personalized health monitoring, human-machine interfaces, soft robots, and implantable biomedical devices. As a core member within the wearable electronics family, flexible strain sensors play an essential role in the structure design and functional optimization. To further enhance the stretchability, flexibility, sensitivity, and electricity performances of the flexible strain sensors, enormous efforts have been done covering the materials design, manufacturing approaches and various applications. Thus, this review summarizes the latest advances in flexible strain sensors over recent years from the material, application, and manufacturing strategies. Firstly, the critical parameters measuring the performances of flexible strain sensors and materials development contains different flexible substrates, new nano- and hybrid- materials are introduced. Then, the developed working mechanisms, theoretical analysis, and computational simulation are presented. Next, based on different material design, diverse applications including human motion detection and health monitoring, soft robotics and human-machine interface, implantable devices, and biomedical applications are highlighted. Finally, synthesis consideration of the massive production industry of flexible strain sensors in the future; different fabrication approaches that are fully expected are classified and discussed.

Effects of Binder and Substrate Materials on the Performance and Reliability of Stretchable Nanocomposite Strain Sensors

In stretchable strain sensors, highly elastic elastomers such as polydimethylsiloxane (PDMS), Ecoflex, and polyurethane are commonly used for binder materials of the nanocomposite and substrates. However, the viscoelastic nature of the elastomers and the interfacial action between nanofillers and binders influence the critical sensor performances, such as repeatability, response, and hysteresis behavior. In this study, we developed a stretchable nanocomposite strain sensor composed of multiwalled carbon nanotubes and a silicone elastomer binder. The effects of binder and substrate materials on the repeatability, response, hysteresis behavior, and long-term endurance of the strain sensors were systematically investigated using stretching, bending, and repeated cyclic bending tests. Three different binder and substrate materials including PDMS, Ecoflex, and a mixture of PDMS/Ecoflex were tested. The stretchable strain sensors showed an excellent linearity and stretchability of more than 130%. Therefore, the long-term endurance of the strain sensors fabricated with Ecoflex binder should be improved. The strain sensors fabricated with Ecoflex binder showed a relatively large variation in electrical resistance during 10,000-cycle bending tests and repeatability errors at large bending angles. The strain sensors fabricated with PDMS binder showed repeatability errors at small bending angles and a slight response delay of 1 second. On the contrary, the strain sensors fabricated with a mixture of PDMS/Ecoflex binder showed excellent repeatability and response characteristics. The PDMS material showed hysteresis behavior; therefore, the strain sensors fabricated with PDMS binder on PDMS substrate exhibited a large hysteresis behavior in the first stretch-release cycle. It was found that the hysteresis behavior of the strain sensors was mainly dependent on substrate materials than on binder materials. The stretchable strain sensors made of the mixture of PDMS/Ecoflex exhibited excellent repeatability, response, hysteresis behavior, and excellent capability in detecting finger and wrist bending.

Flexible and wearable strain sensor based on electrospun carbon sponge/polydimethylsiloxane composite for human motion detection

Flexible and wearable strain sensors have attracted considerable attention due to their potential applications in human motion detection. In this work, the as-fabricated strain sensor was obtained by encapsulation of electrospun carbon sponge (CS) with polydimethylsiloxane (PDMS). The formation mechanism of the self-assembled sponge has been explored. Meanwhile, the piezoresistive properties and the strain sensing mechanism of the CS/PDMS sensor were investigated. The results showed that the as-fabricated CS/PDMS sensor had high piezoresistive sensibility with a maximum gauge factor up to 130.49, superior stability and fast response to various cyclic loading with a tensile strain from 0% up to 40% and a tensile speed range of 2-18 mm min-1. Finally, all the superior performances endow the sensor with abilities to precisely detect pronunciation, human palm motion, wrist joint motion, elbow joint motion, and finger motion in real-time. These results indicate that the strain sensor based on the CS/PDMS could have promising applications in flexible and wearable devices for human motion detection.

Tuning the Piezoresistive Behavior of Poly(Vinylidene Fluoride)/Carbon Nanotube Composites Using Poly(Methyl Methacrylate)

In conductive polymer composites (CPCs), which can be used as both strain sensors and materials with self-diagnosis capabilities for structural health monitoring, the piezoresistive sensitivity can be tuned by changing the electrical filler network structure, mainly influenced by the conductive filler content. Typically, the electrical resistance increases exponentially with strain, and the piezoresistive sensitivity and linearity cannot be improved simultaneously. In this work, we report a facile method to tune the piezoresistive behavior of melt-mixed poly(vinylidene fluoride) (PVDF)/carbon nanotube (CNT, 0.75-2.0 wt %) composites using blending with poly(methyl methacrylate) (PMMA, 5-30 wt %). PVDF and PMMA are completely miscible in the melt state regardless of the proportion. For PVDF-rich blends, the crystallization of PVDF induces separation of the PVDF crystal region from the miscible PVDF/PMMA amorphous blend part during the cooling process. Addition of PMMA tuned the piezoresistive strain behavior and improved the electrical conductivity and toughness at the same time. The PVDF/PMMA/CNT composites show higher sensitivity at low strains than their PVDF/CNT counterparts with comparable initial resistivity. For example, ΔR/R₀ at 5% strain is 18.6% for the PVDF(80)/PMMA(20) blend containing 0.75 wt % CNT versus 11.0% for PVDF containing 1 wt % CNT, both having a volume resistivity of around 10⁴ Ω·cm. The PVDF/PMMA/CNT blend composites also show a less steep exponential increase in the sensing response at higher strains, indicating better linearity. These differences are due to the altered microstructure of the composites and the more homogeneous distribution of CNTs between the smaller and less numerous PVDF crystallites when PMMA is added. The concept of modifying the composite microstructure by adding another commercially available miscible polymer offers a simple and effective way to tune the piezoresistive behavior and improve mechanical properties of CPC sensor materials.

Biocompatible, Flexible Strain Sensor Fabricated with Polydopamine-Coated Nanocomposites of Nitrile Rubber and Carbon Black

A flexible, biocompatible, nitrile butadiene rubber (NBR)-based strain sensor with high stretchability, good sensitivity, and excellent repeatability is presented for the first time. Carbon black (CB) particles were embedded into an NBR matrix via a dissolving-coating technique, and the obtained NBR/CB composite was coated with polydopamine (PDA) to preserve the CB layer. The mechanical properties of the NBR films were found to be significantly improved with the addition of CB and PDA, and the produced composite films were noncytotoxic and highly biocompatible. Strain-sensing tests showed that the uncoated CB/NBR films possess a high sensing range (strain of ∼550%) and good sensitivity (gauge factor of 52.2), whereas the PDA/NBR/CB films show a somewhat reduced sensing range (strain of ∼180%) but significantly improved sensitivity (gauge factor of 346). The hysteresis curves obtained from cyclic strain-sensing tests demonstrate the prominent robustness of the sensor material. Three novel equations were developed to accurately describe the uniaxial and cyclic strain-sensing behavior observed for the investigated strain sensors. Gloves and knee/elbow covers were produced from the films, revealing that the signals generated by different finger, elbow, and knee movements are easily distinguishable, thus confirming that the PDA/NBR/CB composite films can be used in a wide range of wearable strain sensor applications.

Strain‑Sensing Properties of Multi‑Walled Carbon Nanotube/Polydimethylsiloxane Composites with Different Aspect Ratio and Filler Contents

For filler composite systems used in strain sensor applications, piezoresistive effect, strain hysteresis, and repeatability are critical factors, which have to be clearly evaluated and understood. To investigate the effects of the aspect ratio and content of a multi-walled carbon nanotube (MWCNT) on the strain sensor properties of the composite, MWCNT/Polydimethylsiloxane (PDMS) composites with varying filler contents and aspect ratios were fabricated. In order to uniformly disperse MWCNTs on the polymer matrix, we used a three-roll milling method to generate high shear force for de-bundling MWCNTs. Mechanical and electrical properties of the MWCNT composites were evaluated for each case. In addition, through the cyclic stretching test, we optimized the strain-sensing properties of the MWCNT composites by considering their piezoresistive effects and strain hysteresis.

Flexible and Giant Terahertz Modulation Based on Ultra-Strain-Sensitive Conductive Polymer Composites

Dynamic tuning of terahertz (THz) wave has a great potential application as smart THz devices, such as switches, modulators, sensors, and so on. However, the realization of flexible THz modulation with high efficiency is rarely observed, which is nearly absent from the booming development and demands on flexible electronics. Here, we report a flexible THz modulation based on conductive polymer composites composed of thermoplastic polyurethane (TPU) and conductive particles (Ni). By designing the additive content of Ni particles, such a flexible layer exhibits resistivity change of 6-7 orders under tensile strain due to the formation of an electron-transport channel provided by the in situ evolution of the Ni network. It could be used to dynamically control the THz transmission with a giant modulation depth of around 96%, at a high strain operation (up to around 58.5%). Moreover, these characteristics are demonstrated to be available for highly tension sensitive THz spectroscopy and imaging. This work opens up a connection between flexible polymer-based composites and THz dynamic devices. It proposes an unprecedented flexible THz modulation with giant tuning efficiency and provides a scheme for contactless and passive tension sensors.

Highly Stretchable, Elastic, and Sensitive MXene-Based Hydrogel for Flexible Strain and Pressure Sensors

Electronic skin is driving the next generation of cutting-edge wearable electronic products due to its good wearability and high accuracy of information acquisition. However, it remains a challenge to fulfill the requirements on detecting full-range human activities with existing flexible strain sensors. Herein, highly stretchable, sensitive, and multifunctional flexible strain sensors based on MXene- (Ti₃C₂T _x -) composited poly(vinyl alcohol)/polyvinyl pyrrolidone double-network hydrogels were prepared. The uniformly distributed hydrophilic MXene nanosheets formed a three-dimensional conductive network throughout the hydrogel, endowing the flexible sensor with high sensitivity. The strong interaction between the double-network hydrogel matrix and MXene greatly improved the mechanical properties of the hydrogels. The resulting nanocomposited hydrogels featured great tensile performance (2400%), toughness, and resilience. Particularly, the as-prepared flexible pressure sensor revealed ultrahigh sensitivity (10.75 kPa^-1) with a wide response range (0-61.5 kPa), fast response (33.5 ms), and low limit of detection (0.87 Pa). Moreover, the hydrogel-based flexible sensors, with high sensitivity and durability, could be employed to monitor full-range human motions and assembled into some aligned devices for subtle pressure detection, providing enormous potential in facial expression and phonation recognition, handwriting verification, healthy diagnosis, and wearable electronics.

Stumbling through the Research Wilderness, Standard Methods To Shine Light on Electrically Conductive Nanocomposites for Future Healthcare Monitoring

Electrically conductive nanocomposites are an exciting ever-expanding area of research that has yielded many versatile technologies for wearable health devices. Acting as strain-sensing materials, real-time medical diagnostic tools based on these materials may very well lead to a golden age of healthcare. Currently, the goal in research is to create a material that simultaneously has both a large gauge factor (G) and sensing range. However, a weakness in the area of electromechanical research is the lack of standardization in the reporting of the figure of merit (i.e., G) and the need for other intrinsic metrics to give researchers a more complete view of the research landscape of resistive-type sensors. A paradigm shift in the way in which data are reported is required, to push research in the right direction and to facilitate achieving research goals. Here, we report a standardized method for reporting strain-sensing performance and the introduction of the working factor (W) and the Young's modulus (Y) of a material as figures of merit for sensing materials. Using this standard method, we can define the benchmarks for an optimum sensing material (G > 7, W > 1, Y < 300 kPa) using limits set by standard commercial materials and the human body. Using extrapolated data from 200 publications normalized to this standard method, we can review what composite types meet these benchmark limits, what governs composite performances, the literary trends in composites, and the future prospects of research.

Nuomici-Inspired Universal Strategy for Boosting Piezoresistive Sensitivity and Elasticity of Polymer Nanocomposite-Based Strain Sensors

Electrically conductive polymer composites (CPCs) are potential alternatives to conventional strain gauges due to their tunable sensitivity and strain ranges. Currently, to achieve very high piezoresistive sensitivity in thermoplastic-based CPCs with Gauge factors G_F above 20 at low tensile strains (ε ≤ 5%) is a big challenge, but critical for structural health monitoring application in infrastructures. Here, inspired by the unique structures of a famous Chinese food, nuomici, we coat carbon nanotubes (CNTs) onto sticky acrylic rubber (AR) granules (ARG) to form nuomici-like CNT@ARG composite granules, which are employed as unique conductive filler to fabricate highly piezoresistive and flexible CPCs based on poly(vinylidene fluoride) (PVDF). This strategy of localizing CNTs densely on the surface of touching rubbery particles resulted in a much more sensitive elastic conductive network built by the CNT@AR composite and showed a big gain effect. The resultant PVDF/CNT@AR nanocomposites (AR content ranging from 0 to 10 wt %) show extremely high piezoresistive sensitivity at low strain, depending on the AR content. In particular, the G_F value of PVDF with 1.5 wt % CNT@10 wt % AR is 41 at 5% strain, which is more than one magnitude higher than that (ca. 3) of traditional PVDF/CNT nanocomposite sensors. Moreover, the elongation at break increases by about 60% with the addition of 1.5 wt CNT@10 wt % AR. This study introduces a universal effective strategy for tailoring the mechanical properties and strain sensitivity of conductive network in CPCs, which is critical for the fabrication of high-performance strain sensors.

3D printed graphene/polydimethylsiloxane composite for stretchable strain sensor with tunable sensitivity

Materials with tunable and high strain sensitivities have a great potential to be used in next generation flexible electronic devices. Conventional methods, which focus on tailoring the material composition to obtain controllable sensitivities, face the issues of complicated fabrication process and instability, restricting their use in real applications. In this work, we propose the idea of tuning the sensitivities through precisely controlled micro-structures. Based on 3D printing technique, we successfully fabricate graphene/polydimethylsiloxane composites with long range ordered porous structures. The resultant composites present tunable and high gauge factors, along with excellent durability. The tunable sensitivity comes from different strain distributions on the composites under stretching, arising from the different micro-structures constructed. Taking full advantage of the composites in terms of sensitivity and durability, we demonstrate the application of the 3D printed porous sensors as wearable human motion detectors.

Superhydrophobic Electrically Conductive Paper for Ultrasensitive Strain Sensor with Excellent Anticorrosion and Self-Cleaning Property

Recently, a paper-based (PB) strain sensor has turned out to be an ideal substitute for the polymer-based one because of the merits of renewability, biodegradability, and low cost. However, the hygroexpansion and degradation of the paper after absorbing water are the great challenges for the practical applications of the PB strain sensor. Herein, the superhydrophobic electrically conductive paper was fabricated by simply dip-coating the printing paper into the carbon black (CB)/carbon nanotube (CNT)/methyl cellulose suspension and hydrophobic fumed silica (Hf-SiO₂) suspension successively to settle the problem. Because of the existence of ultrasensitive microcrack structures in the electrically conductive CB/CNT layer, the sensor was capable of detecting an ultralow strain as low as 0.1%. During the tension strain range of 0-0.7%, the sensor exhibited a gauge factor of 7.5, almost 3 times higher than that of the conventional metallic-based sensors. In addition, the sensor displayed frequency-independent and excellent durability and reproductivity over 1000 tension cycles. Meanwhile, the superhydrophobic Hf-SiO₂ layer with a micro-nano structure and low surface energy endowed the sensor with outstanding waterproof and self-cleaning properties, as well as great sustainability toward cyclic strain and harsh corrosive environment. Finally, the PB strain sensor could effectively monitor human bodily motions such as finger/elbow joint/throat movement and pulse in real time, especially for the wet or rainy conditions. All these pave way for the fabrication of a high-performance PB strain sensor.

Stretchable elastomer composites with segregated filler networks: effect of carbon nanofiller dimensionality

Electrically conductive elastomer composites (CECs) have great potential in wearable and stretchable electronic applications. However, it is often challenging to trade off electrical conductivity and mechanical flexibility in melt-processed CECs for wearable electronic applications. Here, we develop CECs with high electrical conductivity and mechanical elasticity by controlling the segregated networks of carbon nanofillers formed at the elastomer interface. The carbon nanofiller dimensionality has a significant influence on the electrical and mechanical properties of thermoplastic polyurethane (TPU) composites. For instance, 3D branched carbon nanotubes (carbon nanostructures, CNSs) have a very low percolation threshold (Φ _C = 0.01 wt%), which is about 8-10 times lower than that of 1D carbon nanotubes (CNTs) and 2D graphene nanosheets (GNSs). Besides, the TPU/CNS system has a higher electrical conductivity than other fillers at all filler contents (0.05-2 wt%). On the other hand, TPU/CNT systems can retain high elongation at break, whereas for the TPU/GNS systems elongation at break is severely deteriorated, especially at a high filler content. Different electrical and mechanical properties in the TPU-based CECs enable potential applications in flexible conductors/resistors and stretchable strain sensors, respectively.

Stretchable and sensitive sensor based on carbon nanotubes/polymer composite with serpentine shapes via molding technique

With the rapid development of wearable devices in recent years, stretchable strain sensors based on electrically conductive composites have attracted a great deal of attention owing to their good stretchability and piezoresistivity. However, due to the intrinsic restriction of these types of composites, the conventional stretchable strain sensors cannot do well in all aspect of sensing performance. A stretchable strain sensor based on carbon nanotubes/poly(dimethylsiloxane) composite with the serpentine shape was devised and fabricated. The sensor was readily manufactured through a molding technique. Not only can this sensor distinguish tension strain from transverse or longitudinal direction, but also exhibits good linearity of response to tensile strain. In terms of sensitivity, hysteresis and response time, the stretchable strain sensor showed significant performance. The sensing performance of this proposed stretchable sensor has been demonstrated to be good in this work and it also shows a good prospect for utilization in multifunctional wearable devices.

Graphene/Glycerin Solution-Based Multifunctional Stretchable Strain Sensor with Ultra-High Stretchability, Stability, and Sensitivity

Highly stretchable, flexible, and sensitive strain sensors have promising applications in motion detection-especially multifunctional strain sensors that can detect stretching, bending, compression and twisting. Herein, this study presents a graphene and glycerol solution-based multifunctional sensor with ultra-high stretchability and sensitivity. Owing to the self-lubrication and fluidity of the graphene-glycerol solution, the strain sensors display super stretchability up to 1000%, a maximum gauge factor up to 45.13, and excellent durability for over 10,000 cycles. In addition, the sensor can also rapidly respond to small strains (1%, 5%, 10%) and different stretching rates (12.5%/s, 25%/s, 50%/s, and 100%/s). More impressively, the sensors can measure up to 50 kPa pressure and 180° twisting without any damage. Furthermore, the strain sensors demonstrate their applicability in scenarios involving motion detection, such as that for finger bending, wrist rotating, touching, and drinking water.

Wearable sensors based on colloidal nanocrystals

In recent times, wearable sensors have attracted significant attention in various research fields and industries. The rapid growth of the wearable sensor related research and industry has led to the development of new devices and advanced applications such as bio-integrated devices, wearable health care systems, soft robotics, and electronic skins, among others. Nanocrystals (NCs) are promising building blocks for the design of novel wearable sensors, due to their solution processability and tunable properties. In this paper, an overview of NC synthesis, NC thin film fabrication, and the functionalization of NCs for wearable applications (strain sensors, pressure sensors, and temperature sensors) are provided. The recent development of NC-based strain, pressure, and temperature sensors is reviewed, and a discussion on their strategies and operating principles is presented. Finally, the current limitations of NC-based wearable sensors are discussed, in addition to methods to overcome these limitations.

Strain-sensitive electrical conductivity of carbon nanotube-graphene-filled rubber composites under cyclic loading

Conductive rubber nanocomposites have been attracting interest for strain sensing applications owing to their large deformation and high sensitivity. In this paper, the strain sensing behavior of room temperature vulcanized (RTV) hybrid silicone rubber composites containing carbon nanotubes and graphene was systematically investigated. We studied the effects of the nanofiller content and strain amplitude on the strain sensing behavior of the nanocomposites, and found good stability and durability during cyclic loading. The shoulder peaks appeared in the cyclic loading curves owing to the competition between the reconstruction process of the conductive network during deformation and time-dependent features of the polymer material. Furthermore, our test results of different loading histories indicated that a sufficient recovery time could reduce or even eliminate the shoulder peak. Finally, the mechanical structure with a negative Poisson's ratio is designed to regulate the resistance response of the RTV nanocomposites, exhibiting a monotonic and more sensitive resistance response. Our research results explain the main factors contributing to the shoulder peak phenomenon of conductive nanocomposites and provide a regulation strategy for achieving a monotonic and highly sensitive resistance response.

Thermoplastic Elastomer Systems Containing Carbon Nanofibers as Soft Piezoresistive Sensors

Soft, wearable or printable strain sensors derived from conductive polymer nanocomposites (CPNs) are becoming increasingly ubiquitous in personal-care applications. Common elastomers employed in the fabrication of such piezoresistive CPNs frequently rely on chemically cross-linked polydiene or polysiloxane chemistry, thereby generating relatively inexpensive and reliable sensors that become solid waste upon application termination. Moreover, the shape anisotropy of the incorporated conductive nanoparticles can produce interesting electrical effects due to strain-induced spatial rearrangement. In this study, we investigate the morphological, mechanical, electrical, and electromechanical properties of CPNs generated from thermoplastic elastomer (TPE) triblock copolymer systems containing vapor-grown carbon nanofiber (CNF). Modulus-tunable TPE gels imbibed with a midblock-selective aliphatic oil exhibit well-behaved properties with increasing CNF content, but generally display nonlinear negative piezoresistance at different strain amplitudes and stretch rates due to nanofiber mobility upon CPN strain-cycling. In contrast, a neat TPE possessing low hard-block content yields a distinctive strain-reversible piezoresistive response, as well as low electrical hysteresis, upon cyclic deformation. Unlike their chemically cross-linked analogs, these physically cross-linked and thus environmentally benign CPNs are fully reprocessable by thermal and/or solvent means.

Interface Design Strategy for the Fabrication of Highly Stretchable Strain Sensors

Simultaneously achieving high piezoresistive sensitivity, stretchability, and good electrical conductivity in conductive elastomer composites (CECs) with carbon nanofillers is crucial for stretchable strain sensor and electrode applications. Here, we report a facile and environmentally friendly strategy to realize these three goals at once by using branched carbon nanotubes, also known as the carbon nanostructure (CNS). Inspired by the brick-wall structure, a robust segregated conductive network of a CNS is formed in the thermoplastic polyurethane (TPU) matrix at a very low filler fraction, which renders the composite very good electrical, mechanical, and piezoresistive properties. An extremely low percolation threshold of 0.06 wt %, currently the lowest for TPU-based CECs, is achieved via this strategy. Meanwhile, the electrical conductivity is up to 1 and 40 S/m for the composites with 0.7 and 4 wt % CNS, respectively. Tunable piezoresistive sensitivity dependent on CNS content is obtained, and the composite with 0.7 wt % filler has a gauge factor up to 6861 at strain ε = 660% (elongation at break is 950%). In addition, this strategy also renders the composites' attractive tensile modulus. The composite with 3 wt % CNS shows 450% improvement in Young's modulus versus neat TPU. This work introduces a facile strategy to fabricate highly stretchable strain sensors by designing CNS network structures, advancing understanding of the effects of polymer-filler interfaces on the mechanical and electrical property enhancements for polymer nanocomposites.

Flexible Strain Sensor Based on Carbon Black/Silver Nanoparticles Composite for Human Motion Detection

The demand for flexible and wearable electronic devices with excellent stretchability and sensitivity is increasing, especially for human motion detection. In this work, a simple, low-cost and convenient strategy has been employed to fabricate flexible strain sensor with a composite of carbon black and silver nanoparticles as sensing materials and thermoplastic polyurethane as matrix. The strain sensors thus prepared possesses high stretchability and good sensitivity (gauge factor of 21.12 at 100% tensile strain), excellent static (almost constant resistance variation under 50% strain for 600 s) and dynamic (100 cycles) stability. Compared with bare carbon black-based strain sensor, carbon black/silver nanoparticles composite-based strain sensor shows ~18 times improvement in sensitivity at 100% strain. In addition, we discuss the sensing mechanisms using the disconnection mechanism and tunneling effect which results in high sensitivity of the strain sensor. Due to its good strain-sensing performance, the developed strain sensor is promising in detecting various degrees of human motions such as finger bending, wrist rotation and elbow flexion.

Fabrication of Highly Stretchable, Washable, Wearable, Water-Repellent Strain Sensors with Multi-Stimuli Sensing Ability

Stretchable and wearable sensors with active response to various environmental stimuli possess numerous potential applications in stretchable electronics, motion sensors, environmental monitoring, and so on. Herein, we report a new method to realize control on the local conductive networks of strain sensors, thus, their sensing behavior. These multifunctional crack-based sensors were prepared via spray coating a mixture of carbon nanotube (CNT) and 3-aminopropyltriethoxysilane (KH550) with various ratios onto polydimethylsiloxane (PDMS). The conductive CNT/KH550 layer exhibits brittle mechanical behavior which triggers the formation of cracks upon stretching. This is thought to be responsible for the observed electromechanical behavior. These sensors exhibit adjustable gauge factors of 5-1000, stretchability (ε) of 2-250%, linearity (nonlinearity-linearity) and high durability over 1000 stretching-releasing cycles for mechanical deformation. Washable, wearable, and water-repellent sensors were prepared through such a method to successfully detect human physiological activities. Moreover, the variation in temperature or the presence of solvent can also be detected due to the thermal expansion and swelling of the PDMS layer. It is expected that such a concept could be used to prepare sensors for multiple applications, thanks to its multifunctionality, adjustable and robust performance, simple and low-cost fabrication strategy.

Self-Compensated Driving Circuit for Reducing Drift and Hysteresis in Force Sensing Resistors

Force Sensing Resistors (FSRs) are manufactured from a blend of conductive nanoparticles dispersed in an insulating polymer matrix. FSRs exhibit large amounts of hysteresis and drift error, but currently, a great effort is placed on improving their performance through different techniques applied during sensor manufacturing. In this article, a novel technique for improving the performance of FSRs is presented; the method can be applied to already-manufactured sensors, which is a clear benefit of the proposed procedure. The method is based on driving the sensors with a modified-astable 555 oscillator, in which the oscillation frequency is set from the sensor’s capacitance and resistance. Considering that the sensor’s capacitance and resistance have opposite signs in the drift characteristic, the driving circuit provides self-compensated force measurements over extended periods of time. The feasibility of the driving circuit to reduce hysteresis and to avoid sensitivity degradation is also tested. In order to obtain representative results, the experimental measurements from this study were performed over eight FlexiForce A201-25 sensors.

A photonic sintering derived Ag flake/nanoparticle-based highly sensitive stretchable strain sensor for human motion monitoring

Recently, the demand for stretchable strain sensors used for detecting human motion is rapidly increasing. This paper proposes high-performance strain sensors based on Ag flake/Ag nanocrystal (NC) hybrid materials incorporated into a polydimethylsiloxane (PDMS) elastomer. The addition of Ag NCs into an Ag flake network enhances the electrical conductivity and sensitivity of the strain sensors. The intense localized heating of Ag flakes/NCs is induced by intense pulsed light (IPL) irradiation, to achieve efficient sintering of the Ag NCs within a second, without damaging the PDMS matrix. This leads to significant improvement in the sensor sensitivity. Our strain sensors are highly stretchable (maximum strain = 80%) and sensitive (gauge factor = 7.1) with high mechanical stability over 10 000 stretching cycles under 50% strain. For practical demonstration, the fabrication of a smart glove for detecting the motions of fingers and a sports band for measuring the applied arm strength is also presented. This study provides an effective method for fabricating elastomer-based high-performance stretchable electronics.

Lightweight, compressible and electrically conductive polyurethane sponges coated with synergistic multiwalled carbon nanotubes and graphene for piezoresistive sensors

Lightweight, compressible and highly sensitive pressure/strain sensing materials are highly desirable for the development of health monitoring, wearable devices and artificial intelligence. Herein, a very simple, low-cost and solution-based approach is presented to fabricate versatile piezoresistive sensors based on conductive polyurethane (PU) sponges coated with synergistic multiwalled carbon nanotubes (MWCNTs) and graphene. These sensor materials are fabricated by convenient dip-coating layer-by-layer (LBL) electrostatic assembly followed by in situ reduction without using any complicated microfabrication processes. The resultant conductive MWCNT/RGO@PU sponges exhibit very low densities (0.027-0.064 g cm-3), outstanding compressibility (up to 75%) and high electrical conductivity benefiting from the porous PU sponges and synergistic conductive MWCNT/RGO structures. In addition, the MWCNT/RGO@PU sponges present larger relative resistance changes and superior sensing performances under external applied pressures (0-5.6 kPa) and a wide range of strains (0-75%) compared with the RGO@PU and MWCNT@PU sponges, due to the synergistic effect of multiple mechanisms: "disconnect-connect" transition of nanogaps, microcracks and fractured skeletons at low compression strain and compressive contact of the conductive skeletons at high compression strain. The electrical and piezoresistive properties of MWCNT/RGO@PU sponges are strongly associated with the dip-coating cycle, suspension concentration, and the applied pressure and strain. Fully functional applications of MWCNT/RGO@PU sponge-based piezoresistive sensors in lighting LED lamps and detecting human body movements are demonstrated, indicating their excellent potential for emerging applications such as health monitoring, wearable devices and artificial intelligence.

Highly sensitive and selective multidimensional resistive strain sensors based on a stiffness-variant stretchable substrate

Highly stretchable strain sensors that are capable of collecting complex multi-axial, multidimensional strain information in real time are crucial in practical applications for human motion detection. Here we present a highly sensitive and selective multidimensional resistive strain sensor based on a monolithic integration of a stiffness-variant stretchable substrate and sensing film comprising a cross-shaped silver nanowire percolation network in a single device. The multidimensional strain sensor efficiently distinguishes strains in various directions with a large gauge factor (GF) of >20 and a wide strain-detectable range of up to 60%. The sensor also features a maximum difference in GF between the x- and y-axes of >20 and long-term performance stability for up to 500 strain cycles. The practicality of the sensor as a human motion detector is demonstrated by attaching it directly to a part of the human body and measuring the multidimensional strains that occur during motions in real time.