Stretchable, Sensitive Strain Sensors with a Wide Workable Range and Low Detection Limit for Wearable Electronic Skins

MXene-MWCNT Conductive Network for Long-Lasting Wearable Strain Sensors with Gesture Recognition Capabilities

In this work, a conductive composite film composed of multi-walled carbon nanotubes (MWCNTs) and multi-layer Ti3C2Tx MXene nanosheets is used to construct a strain sensor on sandpaper Ecoflex substrate. The composite material forms a sophisticated conductive network with exceptional electrical conductivity, resulting in sensors with broad detection ranges and high sensitivities. The findings indicate that the strain sensing range of the Ecoflex/Ti3C2Tx/MWCNT strain sensor, when the mass ratio is set to 5:2, extends to 240%, with a gauge factor (GF) of 933 within the strain interval from 180% to 240%. The strain sensor has demonstrated its robustness by enduring more than 33,000 prolonged stretch-and-release cycles at 20% cyclic tensile strain. Moreover, a fast response time of 200 ms and detection limit of 0.05% are achieved. During application, the sensor effectively enables the detection of diverse physiological signals in the human body. More importantly, its application in a data glove that is coupled with machine learning and uses the Support Vector Machine (SVM) model trained on the collected gesture data results in an impressive recognition accuracy of 93.6%.

High-Performance Stretchable Strain Sensors Based on Auxetic Fabrics for Human Motion Detection

Wearable strain sensors play a pivotal role in real-time human motion detection and health monitoring. Traditional fabric-based strain sensors, typically with a positive Poisson's ratio, face challenges in maintaining sensitivity and comfort during human motion due to conflicting resistance changes in different strain directions. In this work, high-performance stretchable strain sensors are developed based on graphene-modified auxetic fabrics (GMAF) for human motion detection in smart wearable devices. The proposed GMAF sensors, with a negative Poisson's ratio achieved through commercially available warp-knitting technology, exhibit an 8-fold improvement in sensitivity compared to conventional plain fabric sensors. The unique auxetic fabric structure enhances sensitivity by synchronizing resistance changes in both wale and course directions. The GMAF sensors demonstrate excellent washability, showing only slight degradation in auxeticity and an acceptable increase in resistance after 10 standard wash cycles. The GMAF sensors maintain stability under different strain levels and various motion frequencies, emphasizing their dynamic performance. The sensors exhibit superior conformability to joint movements, which effectively monitor a full range of motions, including joint bending, sports activities, and subtle actions like coughing and swallowing. The research underscores a promising approach to achieve industrial-scale production of wearable sensors with improved performance and comfort through fabric structure design.

Advanced Multiparallel-Connected Piezoresistive Physical Sensors: Elevating Performance Reliability of Flexible Strain and Pressure Sensors

A physical sensor with a sensing medium comprising multiparallel-connected (MPC) piezoresistive pathways in both the vertical and horizontal directions was developed to achieve improved sensing performance. The MPC sensing medium reduces the total resistance and offsets noise, offering enhanced signal stability and device reliability and providing a high-performance sensing platform. The signal change and gauge factor (GF) of the 3PW-5L strain sensor (comprising three lines and five layers of piezoresistive pathways horizontally and vertically, respectively) were, respectively, 5.9 and 4.7 times higher than those of the 1PW-1L sensor composed of a monosensing pathway; the hysteresis of the detected signal was also significantly reduced. The linearity of the detected signal increased from 0.912 for 1PW-1L to 0.995 for 3PW-5L, indicating a greater sensing reliability. The direction of the applied tensile strain was successfully detected using the MPC sensing medium with an orthogonal configuration. The MPC piezoresistive sensor composing vertically stacked piezoresistive pathways demonstrated excellent performance as a pressure sensor; the 3PW-5L pressure sensor afforded a GF of 0.121 ± 0.002 kPa-1 with a linearity of 0.998 under an applied pressure ≥16.4 kPa. The MPC piezoresistive physical sensor offers a superior sensing performance and should contribute to the future development of wearable sensors and electronic devices.

Ultrasensitive and ultrastretchable metal crack strain sensor based on helical polydimethylsiloxane

The majority of crack sensors do not offer simultaneously both a significant stretchability and an ultrahigh sensitivity. In this study, we present a straightforward and cost-effective approach to fabricate metal crack sensors that exhibit exceptional performance in terms of ultrahigh sensitivity and ultrahigh stretchability. This is achieved by incorporating a helical structure into the substrate through a modeling process and, subsequently, depositing a thin film of gold onto the polydimethylsiloxane substrate via sputter deposition. The metal thin film is then pre-stretched to generate microcracks. The sensor demonstrates a remarkable stretchability of 300%, an exceptional sensitivity with a maximum gauge factor reaching 107, a rapid response time of 158 ms, minimal hysteresis, and outstanding durability. These impressive attributes are attributed to the deliberate design of geometric structures and careful selection of connection types for the sensing materials, thereby presenting a novel approach to fabricating stretchable and highly sensitive crack-strain sensors. This work offers a universal platform for constructing strain sensors with both high sensitivity and stretchability, showing a far-reaching significance and influence for developing next-generation practically applicable soft electronics.

Achieving a Wide-Range Linear Piezoresistive Response in Electrowritten Soft-Hard Polymer Blends via Salami-Inspired Heterostructure Design

Flexible electronics capable of acquiring high-precision signals are in great demand for the development of the internet of things and intelligent artificial. However, it is currently a challenge to simultaneously achieve high signal linearity and sensitivity for stretchable resistive sensors over a wide strain range toward advanced application scenarios requiring high signal accuracy, e.g., sophisticated physiological signal discrimination and displacement measurement. Herein, a film strain sensor, which has an electrical and mechanical dual heterostructure, was fabricated via a direct near-field electrowriting and molecule-guided in situ growth of silver nanoparticles with different concentrations on high-modulus polystyrene domains and low-modulus styrene-butadiene copolymers with a salami-like morphology. Mechanism analyses from both theoretical and experimental investigations reveal that the salami-like heteromodulus microstructure regulates microcrack propagation routes, while the heteroconductivity changes the electron transport paths and amplifies the resistance increase during crack propagation. Therefore, the as-designed strain sensor shows a linear resistive response within ca. 70% strain with a gauge factor of 25, unveiling a simple and scalable strategy for trading off signal linearity and sensitivity over a wide strain range for the fabrication of high-performance linear strain sensors.

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

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

Mechanically Tough and Highly Stretchable Hydrogels Based on Polyurethane for Sensitive Strain Sensor

Hydrogels with flexible and stretchable properties are ideal for applications in wearable sensors. However, traditional hydrogel-based sensors suffer from high brittleness and low electrical sensitivity. In this case, to solve this dilemma, a macromolecular polyurethane crosslinking agent (PCA) was designed and prepared; after that, PCA and two-dimensional (2D) MXene nanosheets were both introduced into a covalently crosslinked network to enhance the comprehensive mechanical and electrochemical properties of the hydrogels. The macromolecular polyurethane crosslinking agent promotes high-tensile strength and highly stretchable capacity by suitable covalent crosslinking. The optimized hydrogel, which exhibited maximum tensile strength and maximum elongation at break, had results of 1.21 MPa and 644%, respectively. Two-dimensional MXene nanosheets provide hydrogel with high electrical conductivity and strain sensitivity, producing a wearable device for the continuous monitoring of human movements and facial microexpressions. This study demonstrated an efficient structure design strategy for building mechanically tough, highly stretchable, and sensitive dual-mode MXenes-based wearable sensors.

Hierarchical Synergistic Structure for High Resolution Strain Sensor with Wide Working Range

Strain sensors have been attracting tremendous attention for the promising application of wearable devices in recent years. However, the trade-off between high resolution, high sensitivity, and broad detection range is a great challenge for the application of strain sensors. Herein, a novel design of hierarchical synergistic structure (HSS) of Au micro cracks and carbon black (CB) nanoparticles is reported to overcome this challenge. The strain sensor based on the designed HSS exhibit high sensitivity (GF > 2400), high strain resolution (0.2%) even under large loading strain, broad detection range (>40%), outstanding stability (>12000 cycles), and fast response speed simultaneously. Further, the experiments and simulation results demonstrate that the carbon black layer greatly changed the morphology of Au micro-cracks, forming a hierarchical structure of micro-scale Au cracks and nano-scale carbon black particles, thus enabling synergistic effect and the double conductive network of Au micro-cracks and CB nanoparticles. Based on the excellent performance, the sensor is successfully applied to monitoring tiny signals of the carotid pulse during body movement, which illustrates the great potential in the application of health monitoring, human-machine interface, human motion detection, and electronic skin.

Skin-Inspired Highly Sensitive Tactile Sensors with Ultrahigh Resolution over a Broad Sensing Range

Flexible tactile sensors with high sensitivity, a broad pressure detection range, and high resolution are highly desired for the applications of health monitoring, robots, and the human-machine interface. However, it is still challenging to realize a tactile sensor with high sensitivity and resolution over a wide detection range. Herein, to solve the abovementioned problem, we demonstrate a universal route to develop a highly sensitive tactile sensor with high resolution and a wide pressure range. The tactile sensor is composed of two layers of microstructured flexible electrodes with high modulus and conductive cotton fabric with low modulus. By optimizing the sensing films, the fabricated tactile sensor shows a high sensitivity of 8.9 × 10⁴ kPa^-1 from 2 Pa to 250 kPa because of the high structural compressibility and stress adaptation of the multilayered composite films. Meanwhile, a fast response speed of 18 ms, an ultrahigh resolution of 100 Pa over 100 kPa, and excellent durability over 20 000 loading/unloading cycles are demonstrated. Moreover, a 6 × 6 tactile sensor array is fabricated and shows promising potential application in electronic skin (e-skin). Therefore, employing multilayered composite films for tactile sensors is a novel strategy to achieve high-performance tactile perception in real-time health monitoring and artificial intelligence.

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

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

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.

Flexible two-dimensional MXene-based antennas

With the growing development of the Internet of things, wearable electronic devices have been extensively applied in civilian and military fields. As an essential component of data transmission in wearable electronics, a flexible antenna is one of the key aspects of research. Conventional metal antennas suffer from a large skin depth, and cannot satisfy the requirements of wearable electronics such as light weight, flexibility, and thinness. Recently, a group of two-dimensional metallic metal carbides (named MXenes) have been explored as building blocks for high-performance flexible antennas with excellent flexibility and superior mechanical strength. The appearance of hydrophilic functional groups at the surface of a MXene allows simple, scalable, and environmentally friendly manufacturing of MXene-based antennas. In this minireview, some pioneering works of MXene-based flexible radio frequency components are summarized, and the existing bottlenecks and the future trends of this promising field are discussed.

Cryopolymerized Polyampholyte Gel with Antidehydration, Self-Healing, and Shape-Memory Properties for Sustainable and Tunable Sensing Electronics

Hydrogel-based wearable flexible electronics are attracting tremendous interest for use in human healthcare. However, many of the existing hydrogel electronics are often susceptible to dehydration, leading to weakened stretchability and inaccurate signal extraction. Besides, hydrogels are desired to be much smarter for self-repairing physical damage and enabling performance manipulation. Herein, we develop a kind of cryopolymerized polyampholyte gels with the multifunctionality of antidehydration, self-healing, and shape-memory for wearable sensing electronics. The antidehydration property is enabled by the incorporation of glycerol, endowing the sensing electronics with excellent stretchability and strain-sensing performance in long-term monitoring. The ionic bonds in the polyampholyte gel possess a dynamic feature regulated by alternant NaCl(aq) and H₂O treatments, laying the foundation for self-healing and shape-memory. As a result, the sensing electronics can automatically repair physical damages without any sacrifice in sensing performance, after healing both conductivity and strain-sensing performance could return to the initial levels. The shape-memory function enables the temporal adjustment of the initial state of the sensing electronics; both the conductivity and sensing performance, for instance, signal intensity, can be manually manipulated. In all, the cryopolymerized polyampholyte gels with antidehydration, self-healing, and shape-memory properties can be an inspiration to develop sustainable and tunable gel-based electronics for human motion monitoring.

Degradable Bioinspired Hypersensitive Strain Sensor with High Mechanical Strength Using a Basalt Fiber as a Reinforced Layer

Flexible strain sensors have received extensive attention due to their broad application prospects. However, a majority of present flexible strain sensors may fail to maintain normal sensing performances upon external loads because of their low strength and thus their performances are affected drastically with increasing loads, which severely restricts large-area popularization and application. Scorpions with hypersensitive vibration slit sensilla are coincident with a similar predicament. Herein, it is revealed that scorpions intelligently use risky slits to detect subtle vibrations, and meanwhile, the distinct layered composites of the main body of this organ prevent catastrophic failure of the sensory structure. Furthermore, the extensive use of flexible sensors will generate a mass of electronic waste just as obsoleting silicon-based devices. Considering mechanical properties and environmental issues, a flexible strain sensor based on an elastomer (Ecoflex)-wrapped fabric with the woven structure was designed and fabricated. Note that introducing a "green" basalt fiber (BF) into a degradable elastomer can effectively avoid environmental issues and significantly enhance the mechanical properties of the sensor. As a result, it shows excellent sensitivity (gauge factor (GF) ∼138.10) and high durability (∼40,000 cycles). Moreover, the reduced graphene oxide (RGO)/BF/Ecoflex flexible strain sensor possesses superior mechanical properties (tensile strength ∼20 MPa) and good flexibility. More significantly, the sensor can maintain normal performances under large external tensions, impact loads, and even underwater environments, providing novel design principles for environmentally friendly flexible sensors under extremely harsh environments.

Serpentine-inspired Strain Sensor with Predictable Cracks for Remote Bio-Mechanical Signal Monitoring

The flexible strain sensors have attracted intense interests due to their application as intelligent wearable electronic devices. However, it is still a huge challenge to achieve the flexible sensor with simultaneous high sensitivity, excellent durability and wide sensing region. In this work, a crack-based strain sensor with paired-serpentine conductive network is fabricated onto flexible film by screen printing. The innovative conductive network exhibits a controlled crack morphology during stretching, which endows the prepared sensor with outstanding sensing characteristics, including the high sensitivity (gauge factor up to 2391.5), wide detection (rang up to 132%), low strain detection limit, fast response time (about 40 ms), as well as excellent durability (more than 2000 stretching/releasing cycles). Benefiting from these excellent performances, full-range human body motions including subtle physiological signals and large motions are accurately detected by the prepared sensor. Besides, wearable electronic equipment integrated with wireless transmitter and the prepared strain sensor shows great potential for remote motion monitoring and intelligent mobile diagnosis for humans. This work provides an effective strategy for the fabrication of the novel strain sensors with highly comprehensive performance. This article is protected by copyright. All rights reserved.

High Sensitivity and a Wide Sensing Range Flexible Strain Sensor Based on the V-Groove/Wrinkles Hierarchical Array

Flexible strain sensors occupying a large part of human body detection and wearable electronics, which have a wide sensing range and high sensitivity, are crucial in fully monitoring human motion signals. This study proposed a strategy to construct flexible strain sensors based on the V-groove/wrinkles hierarchical array. The V-groove array was prepared on a polydimethylsiloxane (PDMS) substrate through mold transfer printing. The gold film was sputtered on the prestretching PDMS substrate, and the V-groove/wrinkles hierarchical array was formed after strain release. Compared with the sensors based on single-scale wrinkle structures and a V-groove array, the fabricated strain sensor with the hierarchical array showed high sensitivity (maximum gauge factor up to 2,557.71) and a wide sensing range (up to 45%). In addition, the dynamic characteristics of the sensor were investigated in detail, indicating that the sensor had a fast response (less than 130 ms), a low detection limit (0.1% strain), and good stability (almost no performance loss after 10,000 cycles). In practical applications, the sensor was used to detect sizable physical motion and weak physiological signals, demonstrating great potential application value in human motion detection. This study could provide new ideas for preparing high-performance flexible strain sensors.