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

Advances in Crack-Based Strain Sensors on Stretchable Polymeric Substrates: Crack Mechanisms, Geometrical Factors, and Functional Structures

This review focuses on deepening the structural understanding of crack-based strain sensors (CBSS) on stretchable and flexible polymeric substrates and promoting sensor performance optimization. CBSS are cutting-edge devices that purposely incorporate cracks into their functional elements, thereby achieving high sensitivity, wide working ranges, and rapid response times. To optimize the performance of CBSS, systematic research on the structural characteristics of cracks is essential. This review comprehensively analyzes the key factors determining CBSS performance such as the crack mechanism, geometrical factors, and functional structures and proposes optimization strategies grounded in these insights. In addition, we explore the potential of numerical analysis and machine learning to offer novel perspectives for sensor optimization. Following this, we introduce various applications of CBSS. Finally, we discuss the current challenges and future prospects in CBSS research, providing a roadmap for next-generation technologies.

Construction of gradient ionogels by self-floatable hyperbranched organosilicon crosslinkers for multi-sensing and wirelessly monitoring physiological signals

Monitoring complex human movements requires the simultaneous detection of strain and pressure, which poses a challenge due to the difficulty in integrating high stretchability and compressive ability into a single material. Herein, a series of hyperbranched polysiloxane crosslinkers (HPSis) with self-floating abilities are designed and synthesized. Taking advantage of the self-floating capabilities of HPSis, ionogels with gradient composition distribution and conductivities are constructed by in situ one-step photopolymerization, and possess satisfactory stretchability, high compressibility and excellent resilience. The gradient-ionogel-based strain sensor exhibits extraordinary pressure sensitivity (19.33 kPa-1), high strain sensitivity (GF reaches 2.5) and temperature sensing ability, enabling the monitoring of the angles and direction of joint movements, transmitting Morse code and wirelessly detecting bioelectrical signals. This study may inspire the design of development of multi-function flexible electronics.

A flexible dual-mode sensor with decoupled strain and temperature sensing for smart robots

Flexible dual mode strain-temperature sensors that mimic human skin functions are highly desired for wearable devices and intelligent robots. However, integrating dual sensing characteristics into a single sensor for simultaneous and decoupled strain-temperature detection still remains a challenge. Herein, we report a flexible dual-modal sensor that uses a "neutral surface" structural design technique to integrate an independently prepared temperature sensing layer (TSL) and strain sensing layer (SSL), for simultaneous monitoring of strain and temperature, in a decoupled manner. The TSL consists of a PDMS/BaTiO3 based dielectric layer whose dielectric constant and thickness change in response to temperature fluctuations. The SSL consists of a resistive type Ni80Cr20 film whose resistance changes in response to external strain. After optimizing the temperature and strain sensing characteristics of the TSL and SSL, the obtained dual-modal flexible sensor has shown a broad temperature sensing range (30 to 200 °C), with high temperature sensitivity (-160.90 fF °C-1), excellent linearity (0.998), and highly discernible temperature resolution (0.1 °C). Additionally, the sensor has also exhibited a wide strain monitoring range (20 to 1000 με), good strain resolution (20 με or 0.002%), and a fast strain response time (54 ms). When practically demonstrated, our sensor has successfully shown independent perception of strain and temperature, which highlights its promising application potential in the fields of smart robotics and intelligent prosthetics.

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

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

Anisotropic V-Groove/Wrinkle Hierarchical Arrays for Multidirectional Strain Sensors with High Sensitivity and Exceptional Selectivity

Flexible strain sensors have been continuously optimized and widely used in various fields such as health monitoring, motion detection, and human-machine interfaces. There is a higher demand for sensors that can sensitively identify both the strain amplitude and direction in real-time to adapt to complex human movements. This study proposes a flexible strain sensor construction strategy based on V-groove/wrinkle hierarchical structures via a facile and scalable prestretching approach. A gold film is sputtered on a V-groove structure soft substrate under a vertical biaxial prestrain. When the strain is released, a variety of wondrous V-groove/wrinkle hierarchical structures are formed. The microstructure and the properties of the resulting sensor can be controlled by adjusting the prestrain, which has obvious anisotropic response characteristics and exhibits high sensitivity (maximum gauge factor up to 20,727.46) and a wide sensing range (up to 51%). In addition, the resulting multidirectional sensor based on double-sided microstructures has an exceptional directional selectivity of 67.39, at an advanced level among all stretchable multidirectional strain sensors reported so far. The sensor can detect human motion signals and distinguish motion patterns, proving its great potential in the field of human motion detection and laying a foundation for high-performance wearable devices.

A Highly Sensitive Strain Sensor with Wide Linear Sensing Range Prepared on a Hybrid-Structured CNT/Ecoflex Film via Local Regulation of Strain Distribution

With the development of information technology, high-performance wearable strain sensors with high sensitivity and stretchability have played a significant role in motion detection. However, many high-sensitivity and outstanding-stretchability strain sensors possess a limited linear sensing range, which limits the enhancement of the flexible strain sensors' performance. Herein, we develop a hybrid-structured carbon nanotube (CNT)/Ecoflex strain sensor with laser-engraved grooves along with punched circular holes in a composite CNT/Ecoflex film by vacuum filtration and permeation. By optimizing the distribution of grooves and circular holes, the strain in the sensing layer can be locally regulated, which alters the morphology of cracks under strain and allows the hybrid-structured CNT/Ecoflex strain sensor to simultaneously exhibit high sensitivity (GF = 43.8) as well as a wide linear sensing range (200%). On the basis of excellent performance, the hybrid-structured CNT/Ecoflex strain sensor is capable of detecting movements in various parts of the human body, including movements of larynx and joint bending.

A double-crack structure for bionic wearable strain sensors with ultra-high sensitivity and a wide sensing range

Flexible strain sensors are crucial in fully monitoring human motion, and they should have a wide sensing range and ultra-high sensitivity. Herein, inspired by lyriform organs, a flexible strain sensor based on the double-crack structure is designed. An MXene layer and an Au layer with cracks are constructed on both sides of the insulated polydimethylsiloxane (PDMS) film, forming an equivalent parallel circuit that guarantees the integrity of the conductive path under a large strain. The rapid disconnection of the crack junctions causes a significant change in the resistance value. Due to the effect of cracks on the conductive path, the sensitivity of the sensor is largely improved. Benefiting from the double-crack structure, the as-obtained sensor shows ultra-high sensitivity (maximum gauge factor of up to 14 373.6), a wide working range (up to 21%), a fast response time (183 ms) and excellent dynamical stability (almost no performance loss after 1000 stretching cycles and different frequency cycles). In practical applications, the sensor is applied to different parts of the human body to sense the deformation of the skin, demonstrating its great potential application value in human physiological detection and the human-machine interaction. This study can provide new ideas for preparing high-performance flexible strain sensors.

Deformation-Induced Photoprogrammable Pattern of Polyurethane Elastomers Based on Poisson Effect

Elastomers with high aspect ratio surface patterns are a promising class of materials for designing soft machines in the future. Here, a facile method for fabricating surface patterns on polyurethane elastomer by subtly utilizing the Poisson effect and gradient photocrosslinking is demonstrated. By applying uniaxial tensile strains, the aspect ratio of the surface patterns can be optionally manipulated. At prestretched state, the pattern on the polyurethane elastomer can be readily constructed through compressive stress, resulting from the gradient photocrosslinking via selective photodimerization of an anthracene-functionalized polyurethane elastomer (referred to as ANPU). The macromolecular aggregation structures during stretching deformation significantly contribute to the fabrication of high aspect ratio surface patterns. The insightful finite element analysis well demonstrates that the magnitude and distribution of internal stress in the ANPU elastomer can be regulated by selectively gradient crosslinking, leading to polymer chains migrate from the exposed region to the unexposed region, thereby generating a diverse array of surface patterns. Additionally, the periodic surface patterns exhibit tunable structural color according to the different stretching states and are fully reversible over multiple cycles, opening up avenues for diverse applications such as smart displays, stretchable strain sensors, and anticounterfeiting devices.

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.

High-Fidelity, Low-Hysteresis Bionic Flexible Strain Sensors for Soft Machines

Stretchable flexible strain sensors based on conductive elastomers are rapidly emerging as a highly promising candidate for popular wearable flexible electronic and soft-mechanical sensing devices. However, due to the intrinsic limitations of low fidelity and high hysteresis, existing flexible strain sensors are unable to exploit their full application potential. Herein, a design strategy for a successive three-dimensional crack conductive network is proposed to cope with the uncoordinated variation of the output resistance signal arising from the conductive elastomer. The electrical characteristics of the sensor are dominated by the successive crack conductive network through a greater resistance variation and a concise sensing mechanism. As a result, the developed elastomer bionic strain sensors exhibit excellent sensing performance in terms of a smaller overshoot response, a lower hysteresis (∼2.9%), and an ultralow detection limit (0.00179%). What's more, the proposed strategy is universal and applicable to many conductive elastomers with different conductive fillers (including 0-D, 1-D, and 2-D conductive fillers). This approach improves the sensing signal accuracy and reliability of conductive elastomer strain sensors and holds promising potential for various applications in the fields of e-skin and soft robotic systems.

Micro-/Nanohierarchical Structures Physically Engineered on Surfaces: Analysis and Perspective

The high demand for micro-/nanohierarchical structures as components of functional substrates, bioinspired devices, energy-related electronics, and chemical/physical transducers has inspired their in-depth studies and active development of the related fabrication techniques. In particular, significant progress has been achieved in hierarchical structures physically engineered on surfaces, which offer the advantages of wide-range material compatibility, design diversity, and mechanical stability, and numerous unique structures with important niche applications have been developed. This review categorizes the basic components of hierarchical structures physically engineered on surfaces according to function/shape and comprehensively summarizes the related advances, focusing on the fabrication strategies, ways of combining basic components, potential applications, and future research directions. Moreover, the physicochemical properties of hierarchical structures physically engineered on surfaces are compared based on the function of their basic components, which may help to avoid the bottlenecks of conventional single-scale functional substrates. Thus, the present work is expected to provide a useful reference for scientists working on multicomponent functional substrates and inspire further research in this field.

High-performance flexible strain sensors based on silver film wrinkles modulated by liquid PDMS substrates

Flexible strain sensors based on controllable surface microstructures in film-substrate systems can be extensively applied in high-tech fields such as human-machine interfaces, electronic skins, and soft robots. However, the rigid functional films are susceptible to structural destruction and interfacial failure under large strains or high loading speeds, limiting the stability and durability of the sensors. Here we report on a facile technique to prepare high-performance flexible strain sensors based on controllable wrinkles by depositing silver films on liquid polydimethylsiloxane (PDMS) substrates. The silver atoms can penetrate into the surface of liquid PDMS to form an interlocking layer during deposition, enhancing the interfacial adhesion greatly. After deposition, the liquid PDMS is spontaneously solidified to stabilize the film microstructures. The surface patterns are well modulated by changing film thickness, prepolymer-to-crosslinker ratio of liquid PDMS, and strain value. The flexible strain sensors based on the silver film/liquid PDMS system show high sensitivity (above 4000), wide sensing range (∼80%), quick response speed (∼80 ms), and good stability (above 6000 cycles), and have a broad application prospect in the fields of health monitoring and motion tracking.

Anisotropic and Highly Sensitive Flexible Strain Sensors Based on Carbon Nanotubes and Iron Nanowires for Human-Computer Interaction Systems

Flexible strain sensors for multi-directional strain detection are crucial in complicated hman-computer interaction (HCI) applications. However, enhancing the anisotropy and sensitivity of the sensors for multi-directional detection in a simple and effective method remains a significant issue. Therefore, this study proposes a flexible strain sensor with anisotropy and high sensitivity based on a high-aspect-ratio V-groove array and a hybrid conductive network of iron nanowires and carbon nanotubes (Fe NWs/CNTs). The sensor exhibits significant anisotropy, with a difference in strain detection sensitivity of up to 35.92 times between two mutually perpendicular directions. Furthermore, the dynamic performance of the sensor shows a good response rate, ranging from 223 ms to 333 ms. The sensor maintains stability and consistent performance even after undergoing 1000 testing cycles. Additionally, the constructed flexible strain sensor is tested using the remote control application of a trolley, demonstrating its high potential for usage in practical HCI systems. This research offers a significant competitive advantage in the development of flexible strain sensors in the field of HCI.

Wrinkled Interfaces: Taking Advantage of Anisotropic Wrinkling to Periodically Pattern Polymer Surfaces

Periodically patterned surfaces can cause special surface properties and are employed as functional building blocks in many devices, yet remaining challenges in fabrication. Advancements in fabricating structured polymer surfaces for obtaining periodic patterns are accomplished by adopting "top-down" strategies based on self-assembly or physico-chemical growth of atoms, molecules, or particles or "bottom-up" strategies ranging from traditional micromolding (embossing) or micro/nanoimprinting to novel laser-induced periodic surface structure, soft lithography, or direct laser interference patterning among others. Thus, technological advances directly promote higher resolution capabilities. Contrasted with the above techniques requiring highly sophisticated tools, surface instabilities taking advantage of the intrinsic properties of polymers induce surface wrinkling in order to fabricate periodically oriented wrinkled patterns. Such abundant and elaborate patterns are obtained as a result of self-organizing processes that are rather difficult if not impossible to fabricate through conventional patterning techniques. Focusing on oriented wrinkles, this review thoroughly describes the formation mechanisms and fabrication approaches for oriented wrinkles, as well as their fine-tuning in the wavelength, amplitude, and orientation control. Finally, the major applications in which oriented wrinkled interfaces are already in use or may be prospective in the near future are overviewed.

In Situ Polymerized MXene/Polypyrrole/Hydroxyethyl Cellulose-Based Flexible Strain Sensor Enabled by Machine Learning for Handwriting Recognition

Flexible strain sensors have significant progress in the fields of human-computer interaction, medical monitoring, and handwriting recognition, but they also face many challenges such as the capture of weak signals, comprehensive acquisition of the information, and accurate recognition. Flexible strain sensors can sense externally applied deformations, accurately measure human motion and physiological signals, and record signal characteristics of handwritten text. Herein, we prepare a sandwich-structured flexible strain sensor based on an MXene/polypyrrole/hydroxyethyl cellulose (MXene/PPy/HEC) conductive material and a PDMS flexible substrate. The sensor features a wide linear strain detection range (0-94%), high sensitivity (gauge factor 357.5), reliable repeatability (>1300 cycles), ultrafast response-recovery time (300 ms), and other excellent sensing properties. The MXene/PPy/HEC sensor can detect human physiological activities, exhibiting excellent performance in measuring external strain changes and real-time motion detection. In addition, the signals of English words, Arabic numerals, and Chinese characters handwritten by volunteers measured by the MXene/PPy/HEC sensor have unique characteristics. Through machine learning technology, different handwritten characters are successfully identified, and the recognition accuracy is higher than 96%. The results show that the MXene/PPy/HEC sensor has a significant impact in the fields of human motion detection, medical and health monitoring, and handwriting recognition.

Piezoresistive Fibers with Large Working Factors for Strain Sensing Applications

Piezoresistive fibers with large working factors remain of great interest for strain sensing applications involving large strains, yet difficult to achieve. Here, we produced strain-sensitive fibers with large working factors by dip-coating nanocomposite piezoresistive inks on surface-modified polyether block amide (PEBA) fibers. Surface modification of neat PEBA fibers was carried out with polydopamine (PDA) while nanocomposite conductive inks consisted of styrene-ethylene-butylene-styrene (SEBS) elastomer and carbon black (CB). As such, the deposition of piezoresistive coatings was enabled through nonconventional hydrogen-bonding interactions. The resultant fibers demonstrated well-defined piezoresistive linear relationships, which increased with CB filler loading in SEBS. In addition, gauge factors decreased with increasing CB mass fractions from ∼15 to ∼7. Furthermore, we used the fatigue theory to predict the endurance limit (C_e) of our fibers toward resistance signal stability. Such a piezoresistive performance allowed us to explore the application of our fibers as strain sensors for monitoring the movement of finger joints.

Bioinspired Dual-Mode Stretchable Strain Sensor Based on Magnetic Nanocomposites for Strain/Magnetic Discrimination

Recently, flexible stretchable sensors have been gaining attention for their excellent adaptability for electronic skin applications. However, the preparation of stretchable strain sensors that achieve dual-mode sensing while still retaining ultra-low detection limit of strain, high sensitivity, and low cost is a pressing task. Herein, a high-performance dual-mode stretchable strain sensor (DMSSS) based on biomimetic scorpion foot slit microstructures and multi-walled carbon nanotubes (MWCNTs)/graphene (GR)/silicone rubber (SR)/Fe₃ O₄ nanocomposites is proposed, which can accurately sense strain and magnetic stimuli. The DMSSS exhibits a large strain detection range (≈160%), sensitivity up to 100.56 (130-160%), an ultra-low detection limit of strain (0.16% strain), and superior durability (9000 cycles of stretch/release). The sensor can accurately recognize sign language movement, as well as realize object proximity information perception and whole process information monitoring. Furthermore, human joint movements and micro-expressions can be monitored in real-time. Therefore, the DMSSS of this work opens up promising prospects for applications in sign language pose recognition, non-contact sensing, human-computer interaction, and electronic skin.

Surface Wrinkling for Flexible and Stretchable Sensors

Recent advances in nanolithography, miniaturization, and material science, along with developments in wearable electronics, are pushing the frontiers of sensor technology into the large-scale fabrication of highly sensitive, flexible, stretchable, and multimodal detection systems. Various strategies, including surface engineering, have been developed to control the electrical and mechanical characteristics of sensors. In particular, surface wrinkling provides an effective alternative for improving both the sensing performance and mechanical deformability of flexible and stretchable sensors by releasing interfacial stress, preventing electrical failure, and enlarging surface areas. In this study, recent developments in the fabrication strategies of wrinkling structures for sensor applications are discussed. The fundamental mechanics, geometry control strategies, and various fabricating methods for wrinkling patterns are summarized. Furthermore, the current state of wrinkling approaches and their impacts on the development of various types of sensors, including strain, pressure, temperature, chemical, photodetectors, and multimodal sensors, are reviewed. Finally, existing wrinkling approaches, designs, and sensing strategies are extrapolated into future applications.

Review of Flexible Wearable Sensor Devices for Biomedical Application

With the development of cross-fertilisation in various disciplines, flexible wearable sensing technologies have emerged, bringing together many disciplines, such as biomedicine, materials science, control science, and communication technology. Over the past few years, the development of multiple types of flexible wearable devices that are widely used for the detection of human physiological signals has proven that flexible wearable devices have strong biocompatibility and a great potential for further development. These include electronic skin patches, soft robots, bio-batteries, and personalised medical devices. In this review, we present an updated overview of emerging flexible wearable sensor devices for biomedical applications and a comprehensive summary of the research progress and potential of flexible sensors. First, we describe the selection and fabrication of flexible materials and their excellent electrochemical properties. We evaluate the mechanisms by which these sensor devices work, and then we categorise and compare the unique advantages of a variety of sensor devices from the perspective of in vitro and in vivo sensing, as well as some exciting applications in the human body. Finally, we summarise the opportunities and challenges in the field of flexible wearable devices.