Highly stretchable sensing array for independent detection of pressure and strain exploiting structural and resistive control

Structural Design and DLP 3D Printing Preparation of High Strain Stable Flexible Pressure Sensors

Flexible pressure sensors are crucial force-sensitive devices in wearable electronics, robotics, and other fields due to their stretchability, high sensitivity, and easy integration. However, a limitation of existing pressure sensors is their reduced sensing accuracy when subjected to stretching. This study addresses this issue by adopting finite element simulation optimization, using digital light processing (DLP) 3D printing technology to design and fabricate the force-sensitive structure of flexible pressure sensors. This is the first systematic study of how force-sensitive structures enhance tensile strain stability of flexible resistive pressure sensors. 18 types of force-sensitive structures have been investigated by finite element design, simultaneously, the modulus of the force-sensitive structure is also a critical consideration as it exerts a significant influence on the overall tensile stability of the sensor. Based on simulation results, a well-designed and highly stretch-stable flexible resistive pressure sensor has been fabricated which exhibits a resistance change rate of 0.76% and pressure sensitivity change rate of 0.22% when subjected to strains ranging from no tensile strain to 20% tensile strain, demonstrating extremely low stretching response characteristics. This study presents innovative solutions for designing and fabricating flexible resistive pressure sensors that maintain stable sensing performance even under stretch conditions.

Electric Double Layer Based Epidermal Electronics for Healthcare and Human-Machine Interface

Epidermal electronics, an emerging interdisciplinary field, is advancing the development of flexible devices that can seamlessly integrate with the skin. These devices, especially Electric Double Layer (EDL)-based sensors, overcome the limitations of conventional electronic devices, offering high sensitivity, rapid response, and excellent stability. Especially, Electric Double Layer (EDL)-based epidermal sensors show great potential in the application of wearable electronics to detect biological signals due to their high sensitivity, fast response, and excellent stability. The advantages can be attributed to the biocompatibility of the materials, the flexibility of the devices, and the large capacitance due to the EDL effect. Furthermore, we discuss the potential of EDL epidermal electronics as wearable sensors for health monitoring and wound healing. These devices can analyze various biofluids, offering real-time feedback on parameters like pH, temperature, glucose, lactate, and oxygen levels, which aids in accurate diagnosis and effective treatment. Beyond healthcare, we explore the role of EDL epidermal electronics in human-machine interaction, particularly their application in prosthetics and pressure-sensing robots. By mimicking the flexibility and sensitivity of human skin, these devices enhance the functionality and user experience of these systems. This review summarizes the latest advancements in EDL-based epidermal electronic devices, offering a perspective for future research in this rapidly evolving field.

Localizing strain via micro-cage structure for stretchable pressure sensor arrays with ultralow spatial crosstalk

Tactile sensors with high spatial resolution are crucial to manufacture large scale flexible electronics, and low crosstalk sensor array combined with advanced data analysis is beneficial to improve detection accuracy. Here, we demonstrated the photo-reticulated strain localization films (prslPDMS) to prepare the ultralow crosstalk sensor array, which form a micro-cage structure to reduce the pixel deformation overflow by 90.3% compared to that of conventional flexible electronics. It is worth noting that prslPDMS acts as an adhesion layer and provide spacer for pressure sensing. Hence, the sensor achieves the sufficient pressure resolution to detect 1 g weight even in bending condition, and it could monitor human pulse under different states or analyze the grasping postures. Experiments show that the sensor array acquires clear pressure imaging and ultralow crosstalk (33.41 dB) without complicated data processing, indicating that it has a broad application prospect in precise tactile detection.

Intentional Blocking Based Photoelectric Soft Pressure Sensor with High Sensitivity and Stability

Soft pressure sensors have recently attracted considerable attention because of their applications in human-machine interface, soft robotics, and prosthetics. However, there remain some challenges in achieving satisfactory performance (e.g., high sensitivity, wide sensing range, high stability) for soft pressure sensors. This article reports an intentional blocking based photoelectric pressure sensor. Two different blocking methods are investigated: the single-row-pyramid blocking and the double-row-pyramid blocking. The sensor has a simple structure, which is made of a light-emitting diode, photosensitive element, and silicone sensor shell. Experiments demonstrate that the sensor has a high sensitivity (the maximum sensitivity is 48.07 kPa^-1, and the minimum measurement pressure is 0.8 Pa), large pressure-sensing range (the sensing range is up to 120 kPa), superior stability (a drift about 0.4% over 12,130 repetitive cycles at 0-80 kPa), low drift (< ±0.2% in different 3-day testing), negligible hysteresis, and high signal-to-noise ratio (over 55 dB). By mounting the pressure sensor at the end of a robotic arm, the robot can detect subtle collisions (such as touching a balloon through a pinpoint). In addition, this article fabricates a tactile glove based on the proposed pressure sensor and shows the application of this glove for music playing and object weighing. This study provides a new structure for photoelectric sensors to increase sensitivity and also provides a more convenient way to fabricate photoelectric pressure sensors.

Recent progress in strain-engineered elastic platforms for stretchable thin-film devices

Strain-engineered elastic platforms that can efficiently distribute mechanical stress under deformation offer adjustable mechanical compliance for stretchable electronic systems. By fully exploiting strain-free regions that are favourable for fabricating thin-film devices and interconnecting with reliably stretchable conductors, various electronic systems can be integrated onto stretchable platforms with the assistance of strain engineering strategies. Over the last decade, applications of multifunctional stretchable thin-film devices simultaneously exhibiting superior electrical and mechanical performance have been demonstrated, shedding light on the realization of further reliable human-machine interfaces. This review highlights recent developments in enabling technologies for strain-engineered elastic platforms. In particular, representative approaches to realize strain-engineered substrates and stretchable interconnects in island-bridge configurations are introduced from the perspective of the material homogeneity and structural design of the substrate. State-of-the-art achievements in sophisticated stretchable electronic devices on strain-engineered elastic platforms are also presented, such as stretchable sensors, energy devices, thin-film transistors, and displays, and then, the challenges and outlook are discussed.

High Density Resistive Array Readout System for Wearable Electronics

This work presents a wearable sensing system for high-density resistive array readout. The system comprising readout electronics for a high-density resistive sensor array and a rechargeable battery, was realized in a wristband. The analyzed data with the proposed system can be visualized using a custom graphical user interface (GUI) developed in a personal computer (PC) through a universal serial bus (USB) and using an Android app in smartphones via Bluetooth Low Energy (BLE), respectively. The readout electronics were implemented on a printed circuit board (PCB) and had a compact dimension of 3 cm × 3 cm. It was designed to measure the resistive sensor with a dynamic range of 1 KΩ–1 MΩ and detect a 0.1% change of the base resistance. The system operated at a 5 V supply voltage, and the overall system power consumption was 95 mW. The readout circuit employed a resistance-to-voltage (R-V) conversion topology using a 16-bit analog-to-digital converter (ADC), integrated in the Cypress Programmable System-on-Chip (PSoC^®) 5LP microcontroller. The device behaves as a universal-type sensing system that can be interfaced with a wide variety of resistive sensors, including chemiresistors, piezoresistors, and thermoelectric sensors, whose resistance variations fall in the target measurement range of 1 KΩ–1 MΩ. The system performance was tested with a 60-resistor array and showed a satisfactory accuracy, with a worst-case error rate up to 2.5%. The developed sensing system shows promising results for applications in the field of the Internet of things (IoT), point-of-care testing (PoCT), and low-cost wearable devices.

Recent Advances in Wearable Optical Sensor Automation Powered by Battery versus Skin-like Battery-Free Devices for Personal Healthcare-A Review

Currently, old-style personal Medicare techniques rely mostly on traditional methods, such as cumbersome tools and complicated processes, which can be time consuming and inconvenient in some circumstances. Furthermore, such old methods need the use of heavy equipment, blood draws, and traditional bench-top testing procedures. Invasive ways of acquiring test samples can potentially cause patient discomfort and anguish. Wearable sensors, on the other hand, may be attached to numerous body areas to capture diverse biochemical and physiological characteristics as a developing analytical tool. Physical, chemical, and biological data transferred via the skin are used to monitor health in various circumstances. Wearable sensors can assess the aberrant conditions of the physical or chemical components of the human body in real time, exposing the body state in time, thanks to unintrusive sampling and high accuracy. Most commercially available wearable gadgets are mechanically hard components attached to bands and worn on the wrist, with form factors ultimately constrained by the size and weight of the batteries required for the power supply. Basic physiological signals comprise a lot of health-related data. The estimation of critical physiological characteristics, such as pulse inconstancy or variability using photoplethysmography (PPG) and oxygen saturation in arterial blood using pulse oximetry, is possible by utilizing an analysis of the pulsatile component of the bloodstream. Wearable gadgets with “skin-like” qualities are a new type of automation that is only starting to make its way out of research labs and into pre-commercial prototypes. Flexible skin-like sensing devices have accomplished several functionalities previously inaccessible for typical sensing devices due to their deformability, lightness, portability, and flexibility. In this paper, we studied the recent advancement in battery-powered wearable sensors established on optical phenomena and skin-like battery-free sensors, which brings a breakthrough in wearable sensing automation.

Sensation and Perception of a Bioinspired Flexible Smart Sensor System

The somatosensory system helps the human body to become aware of various stimuli and to interact with its surroundings. Humans are able to identify and to process abundant sensory information quickly due to their unique perception characteristics. As the largest sensory organ, skin has a large number of discrete receptors to sense and to transform stimuli of touch, pressure, pain, temperature, etc. into electrical signals, which are preprocessed at various levels before reaching the brain, greatly reducing the computational burden on the central nervous system. In addition, the conduction speed varies for different stimulus information, which simplifies the parallel processing of a variety of information. In this Perspective, we discuss a bioinspired design for a flexible smart sensor system by simulating the human somatosensory system. In this design, sensors with selective responses, signals separated in time sequences, and hierarchical information processing are adopted to optimize the sensing and perceiving processes, to reduce power consumption, and to improve the speed of a flexible smart sensor system.