Highly Sensitive Flexible Piezoresistive Sensor with 3D Conductive Network

Flexible Pressure Sensors Enhanced by 3D-Printed Microstructures

3D printing has revolutionized the development of flexible pressure sensors by enabling the precise fabrication of diverse microstructures that significantly enhance sensor performance. These advancements have substantially improved key attributes such as sensitivity, response time, and durability, facilitating applications in wearable electronics, robotics, and human-machine interfaces. This review provides a comprehensive analysis of the sensing mechanisms of these sensors, emphasizing the role of microstructures, such as micro-patterned, microporous, and hierarchical designs, in optimizing performance. The advantages of 3D printing techniques, including direct and indirect fabrication methods, in the creation of complex microstructures with high precision and adaptability are highlighted. Specific applications, including human physiological signal monitoring, motion detection, soft robotics, and emerging applications, are explored to demonstrate the versatility of these sensors. Additionally, this review briefly discusses key challenges, such as material compatibility, optimization difficulties, and environmental stability, as well as emerging trends, such as the integration of advanced technologies, innovative designs, and multidimensional sensing as promising avenues for future advancements. By summarizing recent progress and identifying opportunities for innovation, this review provides critical insights into bridging the gap between research and real-world applications, helping to accelerate the evolution of flexible pressure sensors with sophisticated 3D-printed microstructures.

Graphene-Based, Flexible, Wearable Piezoresistive Sensors with High Sensitivity for Tiny Pressure Detection

Flexible, wearable, piezoresistive sensors have significant potential for applications in wearable electronics and electronic skin fields due to their simple structure and durability. Highly sensitive, flexible, piezoresistive sensors with the ability to monitor laryngeal articulatory vibration supply a new, more comfortable and versatile way to aid communication for people with speech disorders. Here, we present a piezoresistive sensor with a novel microstructure that combines insulating and conductive properties. The microstructure has insulating polystyrene (PS) microspheres sandwiched between a graphene oxide (GO) film and a metallic nanocopper-graphene oxide (n-Cu/GO) film. The piezoresistive performance of the sensor can be modulated by controlling the size of the PS microspheres and doping degree of the copper nanoparticles. The sensor demonstrates a high sensitivity of 232.5 kPa-1 in a low-pressure range of 0 to 0.2 kPa, with a fast response of 45 ms and a recovery time of 36 ms, while also exhibiting excellent stability. The piezoresistive performance converts subtle laryngeal articulatory vibration into a stable, regular electrical signal; in addition, there is excellent real-time monitoring capability of human joint movements. This work provides a new idea for the development of wearable electronic devices, healthcare, and other fields.

Progress in Protein-Based Hydrogels for Flexible Sensors: Insights from Casein

In recent years, the rapid advancement of flexible sensors as the cornerstone of flexible electronics has propelled a flourishing evolution within the realm of flexible electronics. Unlike traditional flexible devices, hydrogel flexible sensors have characteristic advantages such as biocompatibility, adhesion, and adjustable mechanical properties and have similar properties to human skin. Especially, biobased hydrogels have become the preferred substrate material for flexible sensors due to increased environmental pressures caused by the scarcity of petrochemical resources. In this regard, proteins possess advantages such as diverse amino acid compositions, adjustable advanced structures, chemical modifiability, the application of protein engineering techniques, and the ability to respond to various external stimuli. These enable the hydrogels constructed from them to have greater designability, flexibility, and adaptability. As a result, their applications in manufacturing various types of sensors have experienced rapid growth. This work systematically reviews the sensing mechanism of protein-based hydrogels, focusing on the preparation of protein-based hydrogels and the optimization of flexible sensors mainly from the perspective of a typical type of animal-derived protein casein. In addition, while the potential of casein is recognized, the limitations of casein-based hydrogels in flexible sensor applications are explored, and insights are provided into the development trends of next-generation sensors based on casein-based hydrogel materials.

Research Progress of Flexible Piezoresistive Sensors Based on Polymer Porous Materials

Flexible piezoresistive sensors are in high demand in areas such as wearable devices, electronic skin, and human-machine interfaces due to their advantageous features, including low power consumption, excellent bending stability, broad testing pressure range, and simple manufacturing technology. With the advancement of intelligent technology, higher requirements for the sensitivity, accuracy, response time, measurement range, and weather resistance of piezoresistive sensors are emerging. Due to the designability of polymer porous materials and conductive phases, and with more multivariate combinations, it is possible to achieve higher sensitivity and lower detection limits, which are more promising than traditional flexible sensor materials. Based on this, this work reviews recent advancements in research on flexible pressure sensors utilizing polymer porous materials. Furthermore, this review examines sensor performance optimization and development from the perspectives of three-dimensional porous flexible substrate regulation, sensing material selection and composite technology, and substrate and sensing material structure design.

Biocompatible and Biodegradable 3D Graphene/Collagen Fiber Hybrids for High-Performance Conductive Networks and Sensors

Polymer-based flexible conductive materials are crucial for wearable electronics, electronic skin, and other smart materials. However, their development and commercial applications have been hampered by the lack of strain tolerance in the conductive network, poor bonding with polymers, discomfort during wear, and a lack of biocompatibility. This study utilized oil-tanned leather with a natural network structure, high toughness, and high tensile deformation recovery as a structural template. A graphene (Gr) conductive network was then constructed on the collagen network of the leather, with coordination cross-linking between Gr and collagen fibers through aluminum ions (Al3+). A new flexible conductive material (Al-GL) was then constructed. Molecular dynamics simulations and experimental validation revealed the existence of physical adsorption, hydrogen bonding adsorption, and ligand bonding between Al3+, Gr, and collagen fibers. Although we established that the binding sites between Al3+ and collagen fibers were primarily on carboxyl groups (-COOH), the mechanism of chemical bonding between Gr and collagen fibers remains unclear. The Al-GL composite exhibited a high shrinkage temperature (67.4 °C) and low electrical resistance (16.1 kΩ·sq-1), as well as good softness (9.33 mN), biocompatibility, biodegradability (<60 h), and air and moisture permeability. Furthermore, the incorporation of Al3+ resulted in a heightened Gr binding strength on Al-GL, and the resistance remained comparable following 1 h of water washing. The Al-GL sensor prepared by WPU encapsulation not only demonstrated highly sensitive responses to diverse motion signals of the human body but also retained a certain degree of response to external mechanical effects underwater. Additionally, the Al-GL-based triboelectric nanogenerator (Al-GL TENG) exhibited distinct response signals to different materials. The Al-GL prepared by the one-pot method proposed in this study offers a novel approach to combining functional nanofillers and substrate materials, providing a theoretical foundation for collagen fiber-based flexible conductive materials.

Bio-Skin-Inspired Flexible Pressure Sensor Based on Carbonized Cotton Fabric for Human Activity Monitoring

With the development of technology, people's demand for pressure sensors with high sensitivity and a wide working range is increasing. An effective way to achieve this goal is simulating human skin. Herein, we propose a facile, low-cost, and reproducible method for preparing a skin-like multi-layer flexible pressure sensor (MFPS) device with high sensitivity (5.51 kPa-1 from 0 to 30 kPa) and wide working pressure range (0-200 kPa) by assembling carbonized fabrics and micro-wrinkle-structured Ag@rGO electrodes layer by layer. In addition, the highly imitated skin structure also provides the device with an extremely short response time (60/90 ms) and stable durability (over 3000 cycles). Importantly, we integrated multiple sensor devices into gloves to monitor finger movements and behaviors. In summary, the skin-like MFPS device has significant potential for real-time monitoring of human activities in the field of flexible wearable electronics and human-machine interaction.

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.

Toward High-Performance Piezoresistive Polymer Derived SiOC Ceramics through Masked Stereolithography 3D Printing with β-Silicon Carbide Nanopowder Reinforcement

Enhancing the piezoresistivity of polymer-derived silicon oxycarbide ceramics (SiOCPDC ) is of great interest in the advancement of highly sensitive pressure/load sensor technology for use in harsh and extreme working conditions. However, a facile, low cost, and scalable approach to fabricate highly piezoresistive SiOCPDC below 1400 °C still remains a great challenge. Here, the fabrication and enhancement of piezoresistive properties of SiOCPDC reinforced with β-SiC nanopowders (SiCNP ) through masked stereolithography-based 3D-printing and subsequent pyrolysis at 1100 °C are demonstrated. The presence of free carbon in SiCNP augments high piezoresistivity in the fabricated SiCNP -SiOCPDC composites even at lower pyrolysis temperatures. A gauge factor (GF) in the range of 4385-5630 and 6129-8987 with 0.25 and 0.50 wt% of SiCNP , respectively is demonstrated, for an applied pressure range of 0.5-5 MPa at ambient working conditions. The reported GF is significantly higher compared to those of any existing SiOCPDC materials. This rapid and facile fabrication route with significantly enhanced piezoresistive properties makes the 3D-printed SiCNP -SiOCPDC composite a promising high-performance material for the detection of pressure/load in demanding applications. Also, the overall robustness in mechanical properties and load-bearing capability ensures its long-term stability and makes it suitable for challenging and severe environment applications.

Free-standing conductive nickel metal-organic framework nanowires as bifunctional electrodes for wearable pressure sensors and Ni-Zn batteries

Free-standing metal-organic frameworks (MOFs) with controllable structure and good stability are emerging as promising materials for applications in flexible pressure sensors and energy-storage devices. However, the inherent low electrical conductivity of MOF-based materials requires complex preparation processes that involve high-temperature carbonization. This work presents a simple method to grow conductive nickel MOF nanowire arrays on carbon cloth (Ni-CAT@CC) and use Ni-CAT@CC as the functional electrodes for flexible piezoresistive sensor. The resulting sensor is able to monitor human activity, including elbow bending, knee bending, and wrist bending. Besides, the soft-packaged aqueous Ni-Zn battery is assembled with Ni-CAT@CC, a piece of glass microfiber filters, and Zn foil acting as cathode, separator, and anode, respectively. The Ni-Zn battery can be used as a power source for finger pressure monitoring. This work demonstrates free-standing MOF-based nanowires as bifunctional fabric electrodes for wearable electronics.

Advances in Biodegradable Electronic Skin: Material Progress and Recent Applications in Sensing, Robotics, and Human-Machine Interfaces

The rapid growth of the electronics industry and proliferation of electronic materials and telecommunications technologies has led to the release of a massive amount of untreated electronic waste (e-waste) into the environment. Consequently, catastrophic environmental damage at the microbiome level and serious human health diseases threaten the natural fate of the planet. Currently, the demand for wearable electronics for applications in personalized medicine, electronic skins (e-skins), and health monitoring is substantial and growing. Therefore, "green" characteristics such as biodegradability, self-healing, and biocompatibility ensure the future application of wearable electronics and e-skins in biomedical engineering and bioanalytical sciences. Leveraging the biodegradability, sustainability, and biocompatibility of natural materials will dramatically influence the fabrication of environmentally friendly e-skins and wearable electronics. Here, the molecular and structural characteristics of biological skins and artificial e-skins are discussed. The focus then turns to the biodegradable materials, including natural and synthetic-polymer-based materials, and their recent applications in the development of biodegradable e-skin in wearable sensors, robotics, and human-machine interfaces (HMIs). Finally, the main challenges and outlook regarding the preparation and application of biodegradable e-skins are critically discussed in a near-future scenario, which is expected to lead to the next generation of biodegradable e-skins.

SoftSAR: The New Softer Side of Socially Assistive Robots-Soft Robotics with Social Human-Robot Interaction Skills

When we think of "soft" in terms of socially assistive robots (SARs), it is mainly in reference to the soft outer shells of these robots, ranging from robotic teddy bears to furry robot pets. However, soft robotics is a promising field that has not yet been leveraged by SAR design. Soft robotics is the incorporation of smart materials to achieve biomimetic motions, active deformations, and responsive sensing. By utilizing these distinctive characteristics, a new type of SAR can be developed that has the potential to be safer to interact with, more flexible, and uniquely uses novel interaction modes (colors/shapes) to engage in a heighted human-robot interaction. In this perspective article, we coin this new collaborative research area as SoftSAR. We provide extensive discussions on just how soft robotics can be utilized to positively impact SARs, from their actuation mechanisms to the sensory designs, and how valuable they will be in informing future SAR design and applications. With extensive discussions on the fundamental mechanisms of soft robotic technologies, we outline a number of key SAR research areas that can benefit from using unique soft robotic mechanisms, which will result in the creation of the new field of SoftSAR.

Development of a Flexible Integrated Self-Calibrating MEMS Pressure Sensor Using a Liquid-to-Vapor Phase Change

Self-calibration capabilities for flexible pressure sensors are greatly needed for fluid dynamic analysis, structure health monitoring and wearable sensing applications to compensate, in situ and in real time, for sensor drifts, nonlinearity effects, and hysteresis. Currently, very few self-calibrating pressure sensors can be found in the literature, let alone in flexible formats. This paper presents a flexible self-calibrating pressure sensor fabricated from a silicon-on-insulator wafer and bonded on a polyimide substrate. The sensor chip is made of four piezoresistors arranged in a Wheatstone bridge configuration on a pressure-sensitive membrane, integrated with a gold thin film-based reference cavity heater, and two thermistors. With a liquid-to-vapor thermopneumatic actuation system, the sensor can create precise in-cavity pressure for self-calibration. Compared with the previous work related to the single-phase air-only counterpart, testing of this two-phase sensor demonstrated that adding the water liquid-to-vapor phase change can improve the effective range of self-calibration from 3 psi to 9.5 psi without increasing the power consumption of the cavity micro-heater. The calibration time can be further improved to a few seconds with a pulsed heating power.

Wireless Flexible Magnetic Tactile Sensor with Super-Resolution in Large-Areas

Tactile recognition is among the basic survival skills of human beings, and advances in tactile sensor technology have been adopted in various fields, bringing benefits such as outstanding performance in manipulating objects and general human-robot interactions. However, promoting enhanced perception of the existing tactile sensors is limited by their sensor array arrangement and wire-connected design. Here we present a wireless flexible magnetic tactile sensor (FMTS) consisting of a multidirection magnetized flexible film (perception module) and a contactless Hall sensor (signal receiving module). The flexible magnetic film is composed of NdFeB microparticles and soft silicone elastomer microparticles, and it transfers the unambiguous transduction of external force position and magnitude into magnetic signals. Benefiting from the specific magnetization arrangement and clustering algorithm, only one Hall sensor is needed in FMTS to perceive the magnitude and position of the contact spot simultaneously with super-resolution (2.1 mm average error) on a large area (3600 mm²), and the effective working distance is also greatly extended (∼30 mm), allowing for the full softness and adaptability to diverse conditions. We anticipate that this design will promote the development of soft tactile sensors and their integration into human-robot interaction and humanoid robot perception.

Interlinked Microcone Resistive Sensors Based on Self-Assembly Carbon Nanotubes Film for Monitoring of Signals

Flexible pressure sensors still face difficulties achieving a constantly adaptable micronanostructure of substrate materials. Interlinked microcone resistive sensors were fabricated by polydimethylsiloxane (PDMS) nanocone array. PDMS nanocone array was achieved by the second transferring tapered polymethyl methacrylate (PMMA) structure. In addition, self-assembly 2D carbon nanotubes (CNTs) networks as a conducting layer were prepared by a low-cost, dependable, and ultrafast Langmuir−Blodgett (LB) process. In addition, the self-assembled two-dimensional carbon nanotubes (CNTs) network as a conductive layer can change the internal resistance due to pressure. The results showed that the interlinked sensor with a nanocone structure can detect the external pressure by the change of resistivity and had a sensitive resistance change in the low pressure (<200 Pa), good stability through 2800 cycles, and a detection limit of 10 kPa. Based on these properties, the electric signals were tested, including swallowing throat, finger bending, finger pressing, and paper folding. The simulation model of the sensors with different structural parameters under external pressure was established. With the advantages of high sensitivity, stability, and wide detection range, this sensor shows great potential for monitoring human motion and can be used in wearable devices.

Flexible Cotton Fiber-Based Composite Films with Excellent Bending Stability and Conductivity at Cryogenic Temperature

The commonly used metal thin film or resin-based flexible composites cannot meet the requirement of cryogenic flexible conductive functional devices, which may be used in space exploration, biomedicine, and other science and technology fields facing a very low temperature environment, because of their poor fatigue and anti-bending properties at cryogenic temperature. In this work, a composite based on functionalized cotton fibers is proposed to achieve the application requirement of flexible electrical systems at cryogenic temperature. A conductive composite film with optimized strength and flexibility was obtained by controlling the size distribution of cotton fibers and adjusting the interaction force among the cotton fibers. The obtained composite film could endure over 10,000 times of bending at 77 K (-196 °C), with the resistance changing less than ±5%, indicating its excellent mechanical flexibility and electrical stability at cryogenic temperature. Finally, a demonstration was successfully conducted by applying the composite film as a flexible electrical connection to a robot arm, which worked at 77 K. This work might be a reference significance for the application of flexible conductors from room temperature to cryogenic temperature.

Washable Patches with Gold Nanowires/Textiles in Wearable Sensors for Health Monitoring

Textile-based flexible electronic devices have attracted tremendous attention in wearable sensors due to their excellent skin affinity and conformability. However, the washing process of such devices may damage the electronic components. Here, a textile-based piezoresistive sensor with ultrahigh sensitivity was fabricated through the layered integration of gold nanowire (AuNW)-impregnated cotton fabric and silver ink screen-printed nylon fabric electrodes, sealing with Parafilm. The prepared piezoresistive sensing patch exhibits outstanding performance, including high sensitivity (914.970 kPa^-1, <100 Pa), a fast response time (load: 38 ms, recovery: 34 ms), and a low detection limit (0.49 Pa). More importantly, it can maintain a stable signal output even after 30 000 s of loading-unloading cycles. Furthermore, this sensing patch can efficiently detect breathing, pulse, heart rate, and joint movements during the activities. After five cycles of mechanical washing, the piezoresistive performance keeps 90.3%, demonstrating the high feasibility of this sensor in practical applications. This sensor has a simple fabrication, with good fatigue resistance and durability due to its all-fabric core element. It provides a strategy to address the machine-washing issues in textile electronics. This washable textile sensor is expected to show significant potential in future applications of health monitoring, human-machine interfaces, and artificial skin.

Materials, Preparation Strategies, and Wearable Sensor Applications of Conductive Fibers: A Review

The recent advances in wearable sensors and intelligent human-machine interfaces have sparked a great many interests in conductive fibers owing to their high conductivity, light weight, good flexibility, and durability. As one of the most impressive materials for wearable sensors, conductive fibers can be made from a variety of raw sources via diverse preparation strategies. Herein, to offer a comprehensive understanding of conductive fibers, we present an overview of the recent progress in the materials, the preparation strategies, and the wearable sensor applications related. Firstly, the three types of conductive fibers, including metal-based, carbon-based, and polymer-based, are summarized in terms of their principal material composition. Then, various preparation strategies of conductive fibers are established. Next, the primary wearable sensors made of conductive fibers are illustrated in detail. Finally, a robust outlook on conductive fibers and their wearable sensor applications are addressed.

Multifunctional Mechanical Sensing Electronic Device Based on Triboelectric Anisotropic Crumpled Nanofibrous Mats

Integrating multiple mechanical sensing capabilities in one device is highly desired to mimic the amazing functions of human skin, and it demonstrates promising applications in the human-machine interface and wearable robotic exoskeletons. Yet, challenges remain in how to couple the multisensations using as few modules as possible to increase the compactness and conformality of the electronics. Herein, we report a self-powered multiple mechanical sensing electronic device capable of sensing multiple motion modes of strain ratios, strain direction, and pressure. The self-powered property derives from the triboelectric working mechanism of the sensor. The multiple mechanical sensing is realized by utilizing an anisotropic crumpled nanofibrous membrane as the triboelectric layer and ionic conductor as the electrode layer. For strain ratios and pressure sensing, the output voltages of the sensor changed with the changes of these external stimulus with a comparable sensitivity. More importantly, contributed by the anisotropic structure of the designed crumples, the directional strain sensing is realized by the anisotropic sensitivity in three stretched directions.

Aligned wave-like elastomer fibers with robust conductive layers via electroless deposition for stretchable electrode applications

Flexible wearable electronics play an important role in the healthcare industry due to their unique skin affinity, portability and breathability. Despite great progress, it still remains a big challenge to facilely fabricate stretchable electrodes with low resistance, excellent stability and a wide tensile range. Here, we propose a handy and time-saving strategy for the fabrication of elastomeric films consisting of wave-like fibers with a robust conductive layer of silver nanoparticles (AgNPs) immobilized using polydopamine (PDA) and silicone rubber (SR). To realize better stretchability, electrospun thermoplastic polyurethane (TPU) mats with oriented nanofibers were treated via ethanol to achieve a wavy structure, which also allowed for the decoration of AgNP precursors on the TPU surface via PDA assisted electroless deposition (ELD). Therefore, the electrodes achieved a stretchability of 120% with high electrical conductivity (486 S cm^-1). The films with a reduction time of 30 min showed superior electrical conductivity indicated by a resistance increase of only 100% within 50% strain. The TPU/PDA/AgNP/SR composites with a shorter reduction time of silver precursors could monitor human motions as wearable strain sensors with a wide work strain range (0-98%) and a high sensitivity (with a gauge factor (GF) of up to 81.76) for a strain of 80-98%. Therefore, they are an excellent candidate for potential application in prospective stretchable electronics.

Recent Trends and Innovation in Additive Manufacturing of Soft Functional Materials

The growing demand for wearable devices, soft robotics, and tissue engineering in recent years has led to an increased effort in the field of soft materials. With the advent of personalized devices, the one-shape-fits-all manufacturing methods may soon no longer be the standard for the rapidly increasing market of soft devices. Recent findings have pushed technology and materials in the area of additive manufacturing (AM) as an alternative fabrication method for soft functional devices, taking geometrical designs and functionality to greater heights. For this reason, this review aims to highlights recent development and advances in AM processable soft materials with self-healing, shape memory, electronic, chromic or any combination of these functional properties. Furthermore, the influence of AM on the mechanical and physical properties on the functionality of these materials is expanded upon. Additionally, advances in soft devices in the fields of soft robotics, biomaterials, sensors, energy harvesters, and optoelectronics are discussed. Lastly, current challenges in AM for soft functional materials and future trends are discussed.

Wearable Strain Sensors Based on a Porous Polydimethylsiloxane Hybrid with Carbon Nanotubes and Graphene

High-performance flexible strain sensors are urgently needed with the rapid development of wearable intelligent electronics. Here, a bifiller of carbon nanotubes (CNTs) and graphene (GR) for filling flexible porous polydimethylsiloxane (CNT-GR/PDMS) nanocomposites is designed and prepared for strain-sensing applications. The typical microporous structure was successfully constructed using the Soxhlet extraction technique, and the connected CNTs and GR constructed a perfect three-dimensional conductive network in the porous skeleton. As a result, the stretchability and sensitivity of the CNT-GR/PDMS-based strain sensors were well regulated based on the porous structure and the typical synergistic conductive network. Based on the destruction effect of the brittle synergistic conductive network located in the outer and inner layers of the cell skeleton and the contact effect between adjacent cells in different strain ranges, the prepared CNTs-GR/PDMS-based strain sensor exhibited superior gauge factors of 182.5, 45.6, 70.2, and 186.5 in the 0-3, 3-57, 57-90, and 90-120% strain regions, respectively. In addition, this material also exhibited an ultralow detection limit (0.5% strain), a fast response time (60 ms), good stability and durability (10,000 cycles), and frequency-/strain-dependent sensing performances, making it active for the detection of various external environments. Finally, the prepared porous CNTs-GR/PDMS-based strain sensor was attached to the skin to detect various human motions, such as wrist bending, finger bending, elbow bending, and knee bending, thereby demonstrating wide application prospects in smart wearable devices.

Highly Sensitive Interlocked Piezoresistive Sensors Based on Ultrathin Ordered Nanocone Array Films and Their Sensitivity Simulation

Achieving a continuously adjustable micro-nanostructure of sensing materials is crucial and still a challenge for the flexible pressure sensor. We proposed a new method to prepare ultrathin ordered nanocone array films by designing tunable tapered anodized aluminum oxide templates and to prepare highly sensitive flexible pressure sensors by the interlocking nanocone arrays. Meanwhile, the theoretical prediction model of the sensitivity of interlocked nanocone arrays is proposed, and its result shows that the resistance change rate is positively correlated with the height of interlocked nanocone arrays and the contact area between interlocked nanocones. According to the finite element simulation and experimental results, the interlocked ordered nanocone array pressure sensor exhibits a high sensitivity of 268.36 kPa^-1 in the pressure range of 0-200 Pa, an ultralow detection limit of 0.98 Pa, a fast response/recovery time of 48/56 ms, a low hysteresis of ±3.156%, stability under 5000 cycles of loading, and continuity and repeatability under different loads and loading speeds. Furthermore, the pressure sensor can accurately monitor weak wind velocities, wrist torsion and bending movement, and book opening and closing angles. The sensor has broad application prospects in wearable medical monitoring, electronic skin, and human-computer interaction.