Facile fabrication of three-dimensional graphene foam/poly(dimethylsiloxane) composites and their potential application as strain sensor

Multiscale Structural Control by Matrix Engineering for Polydimethylsiloxane Filled Graphene Woven Fabric Strain Sensors

Elastomer cure shrinkage during composite fabrication often induces wrinkling in conductive networks, significantly affecting the performance of flexible strain sensors, yet the specific roles of such wrinkles are not fully understood. Herein, a highly sensitive polydimethylsiloxane-filled graphene woven fabric (PDMS-f-GWF) strain sensor by optimizing the PDMS cure shrinkage through careful adjustment of the base-to-curing-agent ratio is developed. This sensor achieves a gauge factor of ∼700 at 25% strain, which is over 6 times higher than sensors using commercially formulated PDMS. This enhanced sensing performance is attributed to multiscale structural control of the graphene network, enabled by precisely tuned cure shrinkage of PDMS. Using in situ scanning electron microscopy, X-ray scattering, and Raman spectroscopy, an optimized PDMS base-to-curing-agent ratio of 10:0.8 is show that enables interconnected structural changes from atomic to macroscopic scales, including larger "real" strain within the graphene lattice, enhanced flattening of graphene wrinkles, and increased crack density. These findings highlight the critical role of elastomer shrinkage in modulating the multiscale structure of conductive networks, offering new insights into matrix engineering strategies that advance the sensing performance of elastomer-based flexible strain sensors.

Matrix Swelling-Induced Precracking in Graphene Woven Fabric for Ultrasensitive Strain Sensors

The growing demand for highly sensitive flexible strain sensors in applications such as wearable electronics, healthcare monitoring, and environmental sensing has driven the development of materials capable of detecting subtle deformations with high precision. Herein, we introduce a precracked strain sensor based on solvent-swollen graphene woven fabric/polydimethylsiloxane (sGWF/PDMS) composites, designed to achieve ultrahigh gauge factors (GFs) and enhanced responsiveness to minor deformations. By utilizing PDMS swelling to induce network microcracks within the graphene structure, the sGWF/PDMS composites exhibit substantially improved sensitivity compared to traditional graphene-based strain sensors. Systematic in situ SEM analyses reveal that these preexisting microcracks expand readily under minor strain, resulting in rapid resistance changes that underpin the high sensitivity achieved. With GFs reaching up to 82,378 at only 2.8% stretching strain, the sGWF/PDMS composites demonstrate excellent performance across various applications, including human motion detection such as monitoring pulses, eye blinks, and speech-related movements, as well as detecting environmental disturbances such as water surface ripples. These findings highlight matrix-swollen composites as a promising platform for high-sensitivity, low-strain detection, offering great potential for advancements in wearable electronics, environmental monitoring, and other precision sensing applications.

Toward flexible piezoresistive strain sensors based on polymer nanocomposites: a review on fundamentals, performance, and applications

The fundamentals, performance, and applications of piezoresistive strain sensors based on polymer nanocomposites are summarized herein. The addition of conductive nanoparticles to a flexible polymer matrix has emerged as a possible alternative to conventional strain gauges, which have limitations in detecting small strain levels and adapting to different surfaces. The evaluation of the properties or performance parameters of strain sensors such as the elongation at break, sensitivity, linearity, hysteresis, transient response, stability, and durability are explained in this review. Moreover, these nanocomposites can be exposed to different environmental conditions throughout their lifetime, including different temperature, humidity or acidity/alkalinity levels, that can affect performance parameters. The development of flexible piezoresistive sensors based on nanocomposites has emerged in recent years for applications related to the biomedical field, smart robotics, and structural health monitoring. However, there are still challenges to overcome in designing high-performance flexible sensors for practical implementation. Overall, this paper provides a comprehensive overview of the current state of research on flexible piezoresistive strain sensors based on polymer nanocomposites, which can be a viable option to address some of the major technological challenges that the future holds.

Flexible piezo-resistive strain sensors using all-polydimethylsiloxane based hybrid nanocomposites for wearable electronics

We report flexible piezo-resistive strain sensors composed of silver nanoparticle (Ag NP), graphene nanoplatelet (GNP), and multi walled carbon nanotube (MWCNT)-based ternary conductive hybrid nanocomposites as an active sensing layer fabricated using a simple solution processing method on flexible polydimethylsiloxane (PDMS) substrates. The electrical characteristics have been studied in PDMS-based flexible devices having three different kinds of structures, namely Ag NPs/MWCNT/PDMS, GNP/PDMS and Ag NPs/GNP/PDMS. The microscopic analysis of the hybrid nanocomposites is undertaken using field emission scanning electron microscopy. The diameter of the CNTs is found to be in the range of 20-40 nm, whereas the length is determined to be 100-800 nm. The average diameter and length of the GNPs are observed to be 30-50 nm and 100-500 nm, respectively. The crystallite size of the silver nanoparticles in the Ag NPs/MWCNT/PDMS and Ag NPs/GNP/PDMS-based nanocomposites is determined to be 22.8 nm and 29.1 nm, respectively. The prepared sample of Ag NPs shows four distinct peaks in the X-ray diffraction pattern, which correspond to the (111), (200), (220), and (311) face-centered cubic (FCC) crystalline planes. Raman spectroscopy is undertaken to study the fundamental physical properties and chemical analysis of the nanocomposites. Ag NPs/GNP/PDMS-based sensors exhibit superior performance in terms of sensitivity, response and recovery time during breathing/unbreathing analysis. The large surface area of the Ag NPs and GNPs promotes uniform distribution of Ag NPs to fill into the porous GNP surface, thereby facilitating high contact area along with better electron transport in the Ag NPs/GNP/PDMS hybrid nanocomposite-based sensors. The gauge factor (GF), response and recovery time of the Ag NPs/GNP/PDMS hybrid nanocomposite-based sensors are determined to be 221, 130 ms and 119 ms, respectively. The ternary conductive nanocomposite-based sensors are free from the drawbacks of binary nanocomposite-based sensors where the high percolation threshold and poor mechanical behaviour lead to the degradation of the device performance.

Light-driven textile sensors with potential application of UV detection

Smart textiles based on monitoring systems of health conditions, structural behaviour, and external environmental conditions have been presented as elegant solutions for the increasing demands of health care. In this study, cotton fabrics (CFs) were modified by a common strategy with a dipping-padding procedure using reduced graphene oxide (RGO) and a photosensitive dye, spiropyran (SP), which can detect environmental UV light. The morphology of the CF is observed by scanning electron microscopy (SEM) measurements showing that the topography structure of coatings is related to the SP content. The resistance of the textile sensors decreases after UV radiation, which may be attributed to the easier electron transmission on the coatings of the CF. With the increase of SP content, the introduction of a large amount of SP within the composites could cause discontinuous distributions of RGO in the fiber surfaces, preventing electron transmission within the coatings of the RGO. The surface wettability of the coatings and the sweat sensitivity are also studied before and after UV radiation.

Template-Directed Polymerization Strategy for Producing rGO/UHMWPE Composite Aerogels with Tunable Properties

In this paper, we suggest a previously unknown template-directed polymerization strategy for producing graphene/polymer aerogels with elevated mechanical properties, preservation of the nanoscale pore structure, an extraordinary crystallite structure, as well as tunable electrical and hydrophobic properties. The suggested approach is studied using the reduced graphene oxide (rGO)/ultrahigh molecular weight polyethylene (UHMWPE) system as an example. We also develop a novel method of ethylene polymerization with formation of UHMWPE directly on the surface of rGO sheets prestructured as the aerogel template. At a UHMWPE content smaller than 20 wt %, composite materials demonstrate completely reversible deformation and good conductivity. An ultrahigh polymer content (more than 80 wt %) results in materials with pronounced plasticity, improved hydrophobic properties, and a Young's modulus that is more than 200 times larger than that of pure rGO aerogel. Variation of the polymer content makes it possible to tune the electro-conductive properties of the aerogel in the range from 4.8 × 10^-6 to 4.9 × 10^-1 S/m and adjust its hydrophobic properties. The developed approach would make it possible to create composite materials with highly developed nanostructural morphology and advanced properties controlled by the thickness of the polymer layer on the surface of graphene sheets.

From Materials to Devices: Graphene toward Practical Applications

Graphene, as an emerging 2D material, has been playing an important role in flexible electronics since its discovery in 2004. The representative fabrication methods of graphene include mechanical exfoliation, liquid-phase exfoliation, chemical vapor deposition, redox reaction, etc. Based on its excellent mechanical, electrical, thermo-acoustical, optical, and other properties, graphene has made a great progress in the development of mechanical sensors, microphone, sound source, electrophysiological detection, solar cells, synaptic transistors, light-emitting devices, and so on. In different application fields, large-scale, low-cost, high-quality, and excellent performance are important factors that limit the industrialization development of graphene. Therefore, laser scribing technology, roll-to-roll technology is used to reduce the cost. High-quality graphene can be obtained through chemical vapor deposition processes. The performance can be improved through the design of structure of the devices, and the homogeneity and stability of devices can be achieved by mechanized machining means. In total, graphene devices show promising prospect for the practical fields of sports monitoring, health detection, voice recognition, energy, etc. There is a hot issue for industry to create and maintain the market competitiveness of graphene products through increasing its versatility and killer application fields.

3D Graphene Foam by Chemical Vapor Deposition: Synthesis, Properties, and Energy-Related Applications

In this review, we highlight recent advancements in 3D graphene foam synthesis by template-assisted chemical vapor deposition, as well as their potential energy storage and conversion applications. This method offers good control of the number of graphene layers and porosity, as well as continuous connection of the graphene sheets. The review covers all the substrate types, catalysts, and precursors used to synthesize 3D graphene by the CVD method, as well as their most viable energy-related applications.

Heat transfer of graphene foams and carbon nanotube forests under forced convection

The effective dissipation of heat from electronic devices is essential to enable their long-term operation and their further miniaturization. Graphene foams (GF) and carbon nanotube (CNT) forests are promising materials for thermal applications, including heat dissipation, due to their excellent thermal conduction and low thermal interface resistance. Here, we study the heat transfer characteristics of these two materials under forced convection. We applied controlled airflow to heated samples of GF and CNT forests while recording their temperature using infrared micro-thermography. Then, we analyzed the samples using finite-element simulations in conjunction with a genetic optimization algorithm, and we extracted their heat fluxes in both the horizontal and vertical directions. We found that boundary layers have a profound impact on the heat transfer characteristics of our samples, as they reduce the heat transfer in the horizontal direction. The heat transfer in the vertical direction, on the other hand, is dominated by the material conduction and is much higher than the horizontal heat transfer. Accordingly, we uncover the fundamental thermal behavior of GF and CNT forests, paving the way toward their successful integration into thermal applications, including cooling devices.

A flexible piezoresistive strain sensor based on laser scribed graphene oxide on polydimethylsiloxane

Flexible strain sensors are an important constituent in soft robotics, health care devices, and in the defence industry. Strain sensors are characterized by their sensitivity (gauge factor-GF) and sensing range. In flexible strain sensors, simultaneously achieving consistency and high sensitivity has always been challenging. A number of materials and their derivatives have been explored to achieve balanced sensitivity with respect to sensing range with limited results. In this work, a low-cost flexible piezoresistive strain sensor has been developed using reduced graphene oxide (rGO) on polydimethylsiloxane (PDMS). The reduction has been performed using laser scribing, which enables the fabrication of arbitrary structures. After lead-out, the devices were again sandwiched in a layer of PDMS to secure the structures before performing their testing using a locally developed testing rig. Compared to previously reported graphene strain sensors, the devices fabricated in this work show relatively high GF with respect to sensing range. The GF calculated for stretching, bending and torsion was 12.1, 3.5, and 90.3 respectively, for the strain range of 0-140%, 0-130%, and 0-11.1%. A hand test was performed for the detection of joint movement. Change of resistance has been observed indicating muscle motion.

Review of Graphene-Based Textile Strain Sensors, with Emphasis on Structure Activity Relationship

Graphene-based textile strain sensors were reviewed in terms of their preparation methods, performance, and applications with particular attention on its forming method, the key properties (sensitivity, stability, sensing range and response time), and comparisons. Staple fiber strain sensors, staple and filament strain sensors, nonwoven fabric strain sensors, woven fabric strain sensors and knitted fabric strain sensors were summarized, respectively. (i) In general, graphene-based textile strain sensors can be obtained in two ways. One method is to prepare conductive textiles through spinning and weaving techniques, and the graphene worked as conductive filler. The other method is to deposit graphene-based materials on the surface of textiles, the graphene served as conductive coatings and colorants. (ii) The gauge factor (GF) value of sensor refers to its mechanical and electromechanical properties, which are the key evaluation indicators. We found the absolute value of GF of graphene-based textile strain sensor could be roughly divided into two trends according to its structural changes. Firstly, in the recoverable deformation stage, GF usually decreased with the increase of strain. Secondly, in the unrecoverable deformation stage, GF usually increased with the increase of strain. (iii) The main challenge of graphene-based textile strain sensors was that their application capacity received limited studies. Most of current studies only discussed washability, seldomly involving the impact of other environmental factors, including friction, PH, etc. Based on these developments, this work was done to provide some merit to references and guidelines for the progress of future research on flexible and wearable electronics.

3D Graphene Materials: From Understanding to Design and Synthesis Control

Carbon materials, with their diverse allotropes, have played significant roles in our daily life and the development of material science. Following 0D C₆₀ and 1D carbon nanotube, 2D graphene materials, with their distinctively fascinating properties, have been receiving tremendous attention since 2004. To fulfill the efficient utilization of 2D graphene sheets in applications such as energy storage and conversion, electrochemical catalysis, and environmental remediation, 3D structures constructed by graphene sheets have been attempted over the past decade, giving birth to a new generation of graphene materials called 3D graphene materials. This review starts with the definition, classifications, brief history, and basic synthesis chemistries of 3D graphene materials. Then a critical discussion on the design considerations of 3D graphene materials for diverse applications is provided. Subsequently, after emphasizing the importance of normalized property characterization for the 3D structures, approaches for 3D graphene material synthesis from three major types of carbon sources (GO, hydrocarbons and inorganic carbon compounds) based on GO chemistry, hydrocarbon chemistry, and new alkali-metal chemistry, respectively, are comprehensively reviewed with a focus on their synthesis mechanisms, controllable aspects, and scalability. At last, current challenges and future perspectives for the development of 3D graphene materials are addressed.

High-Performance Wearable Strain Sensor Based on Graphene/Cotton Fabric with High Durability and Low Detection Limit

Electronic textiles featuring a controllable strain sensing capability and comfortable wearability have attracted huge interests with the rapid development of wearable strain sensor systems. It is still a great challenge to simultaneously achieve a strain sensor with low cost, biocompatibility, large-area compatibility, and excellent sensing performances. Here, two kinds of cotton fabric-based strain sensors (CFSSs) with different conductive network structures are prepared, i.e., CFSS-90° and CFSS-45° (90° and 45° represent the angles between intertwined direction in cotton yarns and the stretching direction in tension). After multiple dipping processes, graphene nanosheets are deposited onto cotton fabrics, and then, the fabrics are encapsulated by polydimethylsiloxane (PDMS). Morphology analyses reveal that an interpenetrating structure is generated between cotton fabric and PDMS. The strength and elongation at break of CFSS-45° are about 4.5 MPa and 75% strain, which are higher than the counterparts of CFSS-90° (1.75 MPa and 30% strain, respectively). In a uniaxial stretching test, the two strain sensors exhibit excellent linear current-voltage behavior and fast response time (∼90 ms). During the cyclic stretching-releasing test, CFSSs present remarkable reproducibility, durability (10 000 cycles at 30% strain for CFSS-45°), and a sensing capability for detecting very low strain (∼0.4% strain).

Graphether: a two-dimensional oxocarbon as a direct wide-band-gap semiconductor with high mechanical and electrical performances

Although many graphene derivatives have sizable band gaps, their electrical or mechanical properties are significantly degraded due to the low degree of π-conjugation. Besides the π-π conjugation, there exist hyperconjugative interactions arising from the delocalization of σ electrons. Inspired by the structural characteristics of a hyperconjugated molecule, dimethyl ether, we design a two-dimensional oxocarbon (named graphether) by the assembly of dimethyl ether molecules. Our first-principles calculations reveal the following findings: (1) monolayer graphether possesses excellent dynamic and thermal stabilities as demonstrated by its favourable cohesive energy, the absence of soft phonon modes, and high melting point. (2) It has a direct wide-band-gap energy of 2.39 eV, indicating its potential applications in ultraviolet optoelectronic devices. Interestingly, the direct band gap feature is rather robust against the external strains (-10% to 10%) and stacking configurations. (3) Due to the hyperconjugative effect, graphether has the high intrinsic electron mobility. More importantly, its in-plane stiffness (459.8 N m-1) is even larger than that of graphene. (4) The Pt(100) surface exhibits high catalytic activity for the dehydrogenation of dimethyl ether. The electrostatic repulsion serves as a driving force for the rotation and coalescence of two dehydrogenated precursors, which is favourable for the bottom-up growth of graphether. (5) Replacement of the C-C bond with an isoelectronic B-N bond can generate a stable Pmn21-BNO monolayer. Compared with monolayer hexagonal boron nitride, Pmn21-BNO has a moderate direct band gap energy (3.32 eV) and better mechanical property along the armchair direction.

Silver-Coated Poly(dimethylsiloxane) Beads for Soft, Stretchable, and Thermally Stable Conductive Elastomer Composites

We introduce an elastomer composite filled with silver (Ag) flakes and Ag-coated poly(dimethylsiloxane) (PDMS) beads that exhibits electrical conductivity that is 2 orders of magnitude greater than that of elastomers in which the same concentration of Ag filler is uniformly dispersed. In addition to the dramatic enhancement in conductivity, these composites exhibit high mechanical compliance (strain limit, >100%) and robust thermal stability (conductivity change, <10% at 150 °C). The incorporation of Ag-coated PDMS beads introduces an effective phase segregation in which Ag flakes are confined to the "grain boundaries" between the embedded beads. This morphological control aids in the percolation of the Ag flakes and the formation of conductive bridges between neighboring Ag shells. The confinement of Ag flakes also suppresses thermal expansion and changes in electrical conductivity of the percolating networks when the composite is heated. We demonstrate potential applications of thermally stable elastic conductors in wearable devices and soft robotics by fabricating a highly stretchable antenna for a "smart" furnace glove and a strain sensor for soft gripper operation in hot water.

Ultraviolet- and Microwave-Protecting, Self-Cleaning e-Skin for Efficient Energy Harvesting and Tactile Mechanosensing

Smart, self-powered, and wearable e-skin that mimics the pressure sensing property of the human skin is indispensable to boost up cutting edge robotics, artificial intelligence, prosthesis, and health-care monitoring technologies. Here, fabrication of a facile and flexible hybrid piezoelectric e-skin (HPES) with multifunctions of tactile mechanosensing, energy harvesting, self-cleaning, ultraviolet (UV)-protecting, and microwave shielding properties is reported. The principal block of the HPES is an SnO₂ nanosheets@SiO₂ (silica-encapsulated tin oxide nanosheets)/poly(vinylidene fluoride) (PVDF) nanocomposite (SS)-based PES acting as a single unit for simultaneous energy harvesting and tactile mechanosensing. Gentle human finger imparting onto the PES showed outstanding energy conversion efficiency (16.7%) with high power density (550 W·m^-3) and current density (0.40 μA·cm^-2). This device can generate high enough electrical power to directly drive portable electronics like a light-emitting diode (LED) panel (consisting of 85 commercial LEDs) and to charge up capacitors very rapidly. Thin PES mechanosensors demonstrated promising performance for quantitatively detecting static and dynamic pressure stimuli with a high sensitivity of 0.99 V·kPa^-1 and a short response time of 1 ms. PES was also integrated to a health-data glove for precisely monitoring and discriminating fine motions of proximal interphalangeal, metacarpophalangeal, and distal interphalangeal joints of a human finger and bending motion of different human fingers. A (4 × 4) sensing matrix of PES was successfully employed to detect the spatial distribution of static pressure stimuli. The sensing matrix can precisely record the shape and size of an object placed onto it. PES was encapsulated with a nanocomposite film for providing self-cleaning and UV and microwave protection capability to the HPES. The hydrophobic SS film wrapping (water drop contact angle ∼85.6°) of the HPES enables the self-cleaning feature and makes HPES resistive against water and dirt. The HPES was integrated with in-house-made robotic hands, and the responses of the sensors due to grabbing of an object were evaluated. This work explores new prospects for UV- and microwave-protective, self-cleaning e-skin for energy harvesting and mechanosensation, which can eventually boost up the self-powered electronics, robotics, real-time health-care monitoring, and artificial intelligence technologies.

Highly Ordered 3D Porous Graphene Sponge for Wearable Piezoresistive Pressure Sensor Applications

Wearable sensors with excellent flexibility and sensitivity have emerged as a promising field for healthcare, electronic skin, and so forth. Three-dimensional (3D) graphene sponges (GS) have emerged as high-performance piezoresistive sensors; however, problems, such as limited flexibility, high cost, and low sensitivity, remain. Meanwhile, device-level wearable pressure sensors with GS have rarely been demonstrated. In this work, highly ordered 3D porous graphene sponges (OPGSs) were first successfully prepared and controlled through an emulsion method, and then a device-level wearable pressure sensor with high flexibility and sensitivity was assembled with a gold electrode and polydimethylsiloxane into a reliable package. The pH values were carefully controlled to form a stable emulsion and the OPGSs showed a highly ordered 3D structure with ultralow density, high porosity, and conductivity; this resulted in a gauge factor of 0.79-1.46, with 50 % compression strain and excellent long-term reproducibility over 500 cycles of compression-relaxation. Moreover, the well-packaged pressure sensor devices exhibited ultrahigh sensitivity to detect human motions, such as wrist bending, elbow bending, finger bending, and palm flexing. Thus, the developed pressure sensors exhibited great potential in the fields of human-interactive applications, biomechanical systems, electronic skin, and so forth.

Spider-Web-Inspired Stretchable Graphene Woven Fabric for Highly Sensitive, Transparent, Wearable Strain Sensors

Advanced wearable strain sensors with high sensitivity and stretchability are an essential component of flexible and soft electronic devices. Conventional metal- and semiconductor-based strain sensors are rigid, fragile, and opaque, restricting their applications in wearable electronics. Graphene-based percolative structures possess high flexibility and transparency but lack high sensitivity and stretchability. Inspired by the highly flexible spider web architecture, we propose semitransparent, ultrasensitive, and wearable strain sensors made from an elastomer-filled graphene woven fabric (E-GWF) for monitoring human physiological signals. The highly flexible elastomer microskeleton and the hierarchical structure of a graphene tube offer the strain sensor with both excellent sensing and switching capabilities. Two different types of E-GWF sensors, including freestanding E-GWF and E-GWF/polydimethylsiloxane (PDMS) composites, are developed. When their structure is controlled and optimized, the E-GWF strain sensors simultaneously exhibit extraordinary characteristics, such as a high gauge factor (70 at 10% strain, which ascends to 282 at 20%) in respect to other semitransparent or transparent strain sensors, a broad sensing range up to 30%, and excellent linearity. The E-GWF/PDMS composite sensor shows a unique reversible switching behavior at a high strain level of 30-50%, making it a suitable material for fast and reversible strain switching required in many early warning systems. With a view to real-world applications of these sensors and switches, we demonstrate human motion detection and switch controls of light-emitting-diode lamps and liquid-crystal-display circuits. Their unique structure and capabilities can find a wide range of practical applications, such as health monitoring, medical diagnosis, early warning systems for structural failure, and wearable displays.

Carbon Nanostructures as a Multi-Functional Platform for Sensing Applications

The various forms of carbon nanostructures are providing extraordinary new opportunities that can revolutionize the way gas sensors, electrochemical sensors and biosensors are engineered. The great potential of carbon nanostructures as a sensing platform is exciting due to their unique electrical and chemical properties, highly scalable, biocompatible and particularly interesting due to the almost infinite possibility of functionalization with a wide variety of inorganic nanostructured materials and biomolecules. This opens a whole new pallet of specificity into sensors that can be extremely sensitive, durable and that can be incorporated into the ongoing new generation of wearable technology. Within this context, carbon-based nanostructures are amongst the most promising structures to be incorporated in a multi-functional platform for sensing. The present review discusses the various 1D, 2D and 3D carbon nanostructure forms incorporated into different sensor types as well as the novel functionalization approaches that allow such multi-functionality.

Engineering of High-Density Thin-Layer Graphite Foam-Based Composite Architectures with Superior Compressibility and Excellent Electromagnetic Interference Shielding Performance

Three-dimensional (3D) graphene architectures with well-controlled structure and excellent physiochemical properties have attracted considerable interest due to their potential applications in flexible electronic devices. However, the majority of the existing 3D graphene still encounters several drawbacks such as brittleness, non-uniform building units, and limited scale (millimeter or even micrometer), which severely limits its practical applications. Herein, we demonstrate a new scalable technique for the preparation of thin-layer graphite foam (GF) with controllable densities (27.2-69.2 mg cm^-3) by carbonization of polyacrylonitrile using a template-directed thermal annealing approach. By integrating the GF with poly(dimethylsiloxane) (PDMS), macroscopic porous GF@PDMS with variable thin-layer GF contents ranging from 15.9 to 31.7% was further fabricated. Owing to the robust interconnected porous network of the GF and the synergistic effect between GF and PDMS, GF@PDMS with a 15.9% thin-layer GF content exhibited an impressive 254% increase in compressive strength over the bare GF. In addition, such 15.9% GF@PDMS can totally recover after the first compression cycle at a 95% strain and maintain ∼88% recovery even after 1000 compression cycles at an 80% strain, demonstrating its superior compressibility. Moreover, all of the as-prepared GF@PDMS samples possessed high electrical conductivity (up to 34.3 S m^-1), relatively low thermal conductivity (0.062-0.076 W m^-1 K^-1), and excellent electromagnetic interference shielding effectiveness (up to 36.1 dB) over a broad frequency range of 8.2-18 GHz, indicating their great potential as promising candidates for high-performance electromagnetic wave absorption in flexible electronic devices.

Highly Sensitive and Flexible Strain-Pressure Sensors with Cracked Paddy-Shaped MoS2/Graphene Foam/Ecoflex Hybrid Nanostructures

Three-dimensional graphene porous networks (GPNs) have received considerable attention as a nanomaterial for wearable touch sensor applications because of their outstanding electrical conductivity and mechanical stability. Herein, we demonstrate a strain-pressure sensor with high sensitivity and durability by combining molybdenum disulfide (MoS₂) and Ecoflex with a GPN. The planar sheets of MoS₂ bonded to the GPN were conformally arranged with a cracked paddy shape, and the MoS₂ nanoflakes were formed on the planar sheet. The size and density of the MoS₂ nanoflakes were gradually increased by raising the concentration of (NH₄)₂MoS₄. We found that this conformal nanostructure of MoS₂ on the GPN surface can produce improved resistance variation against external strain and pressure. Consequently, our MoS₂/GPN/Ecoflex sensors exhibited noticeably improved sensitivity compared to previously reported GPN/polydimethylsiloxane sensors in a pressure test because of the existence of the conformal planar sheet of MoS₂. In particular, the MoS₂/GPN/Ecoflex sensor showed a high sensitivity of 6.06 kPa^-1 at a (NH₄)₂MoS₄ content of 1.25 wt %. At the same time, it displayed excellent durability even under repeated loading-unloading pressure and bending over 4000 cycles. When the sensor was attached on a human temple and neck, it worked correctly as a drowsiness detector in response to motion signals such as neck bending and eye blinking. Finally, a 3 × 3 tactile sensor array showed precise touch sensing capability with complete isolation of electrodes from each other for application to touch electronic applications.

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

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

Three-Dimensional Graphene Structure for Healable Flexible Electronics Based on Diels-Alder Chemistry

Wearable electronics with excellent stretchability and sensitivity have emerged as a very promising field with wide applications such as e-skin and human motion detection. Although three-dimensional (3D) graphene structures (GS) have been reported for high-performance strain sensors, challenges still remain such as the high cost of GS preparation, low stretchability, and the lack of ability to heal itself. In this paper, we reported a novel self-healing flexible electronics with 3D GS based on Diels-Alder (DA) chemistry. Furfurylamine (FA) was employed as a reducing as well as a modifying agent, forming GS by FA (FAGS)/DA bonds contained polyurethane with the "infiltrate-gel-dry" process. The as-prepared composite exhibited excellent stretchability (200%) and intrinsic conductivity with low incorporation of graphene (about 2 wt %), which could be directly employed for flexible electronics to detect human motions. Besides, the FAGS/DAPU composite exhibited lower temperature retro-DA response for the continuous graphene networks. Highly effective healing of the composites by heat and microwave has been demonstrated successfully.

Sliced graphene foam films for dual-functional wearable strain sensors and switches

The demand for wearable sensors is growing in many emerging fields, such as health monitoring, human-machine interfaces, robotics and personalized medicine. Here, we report the integration of skin-mountable, flexible, stretchable, dual-functional sensors and switches together with silicon-based electronics to create a novel healthcare system. We employ a facile approach to design highly stretchable graphene foam (GF)/PDMS composite films with tunable sensitivities and switching capabilities by simply controlling the thickness of GF. The GF/PDMS composite films deliver a high gauge factor of 24 at a 10% strain, tunable stretchability up to 70% and an excellent on/off switching ratio on the order of 1000. The highly reversible switching capability of the composite films is realized by identifying abnormal resistance changes at strains beyond a threshold value. To bridge the gap between signal transmission, wireless communication and post-processing in wearable devices, the sensors are combined with electronics, allowing data transmission to a smartphone using a custom-developed application consisting of a user-friendly interface. The novel approaches reported here offer a wide range of practical applications, including medical diagnosis, health monitoring and patient healthcare.

Three-Dimensional Graphene Foam Induces Multifunctionality in Epoxy Nanocomposites by Simultaneous Improvement in Mechanical, Thermal, and Electrical Properties

Three-dimensional (3D) macroporous graphene foam based multifunctional epoxy composites are developed in this study. Facile dip-coating and mold-casting techniques are employed to engineer microstructures with tailorable thermal, mechanical, and electrical properties. These processing techniques allow capillarity-induced equilibrium filling of graphene foam branches, creating epoxy/graphene interfaces with minimal separation. Addition of 2 wt % graphene foam enhances the glass transition temperature of epoxy from 106 to 162 °C, improving the thermal stability of the polymer composite. Graphene foam aids in load-bearing, increasing the ultimate tensile strength by 12% by merely 0.13 wt % graphene foam in an epoxy matrix. Digital image correlation (DIC) analysis revealed that the graphene foam cells restrict and confine the deformation of the polymer matrix, thereby enhancing the load-bearing capability of the composite. Addition of 0.6 wt % graphene foam also enhances the flexural strength of the pure epoxy by 10%. A 3D network of graphene branches is found to suppress and deflect the cracks, arresting mechanical failure. Dynamic mechanical analysis (DMA) of the composites demonstrated their vibration damping capability, as the loss tangent (tan δ) jumps from 0.1 for the pure epoxy to 0.24 for ∼2 wt % graphene foam-epoxy composite. Graphene foam branches also provide seamless pathways for electron transfer, which induces electrical conductivity exceeding 450 S/m in an otherwise insulator epoxy matrix. The epoxy-graphene foam composite exhibits a gauge factor as high as 4.1, which is twice the typical gauge factor for the most common metals. Simultaneous improvement in thermal, mechanical, and electrical properties of epoxy due to 3D graphene foam makes epoxy-graphene foam composite a promising lightweight and multifunctional material for aiding load-bearing, electrical transport, and motion sensing in aerospace, automotive, robotics, and smart device structures.

Highly Flexible and Sensitive Wearable E-Skin Based on Graphite Nanoplatelet and Polyurethane Nanocomposite Films in Mass Industry Production Available

Graphene and nanomaterials based flexible pressure sensors R&D activities are becoming hot topics due to the huge marketing demand on wearable devices and electronic skin (E-Skin) to monitor the human body's actions for dedicated healthcare. Herein, we report a facile and efficient fabrication strategy to construct a new type of highly flexible and sensitive wearable E-Skin based on graphite nanoplates (GNP) and polyurethane (PU) nanocomposite films. The developed GNP/PU E-Skin sensors are highly flexible with good electrical conductivity due to their unique binary microstructures with synergistic interfacial characteristics, which are sensitive to both static and dynamic pressure variation, and can even accurately and quickly detect the pressure as low as 0.005 N/50 Pa and momentum as low as 1.9 mN·s with a gauge factor of 0.9 at the strain variation of up to 30%. Importantly, our GNP/PU E-Skin is also highly sensitive to finger bending and stretching with a linear correlation between the relative resistance change and the corresponding bending angles or elongation percentage. In addition, our E-Skin shows excellent sensitivity to voice vibration when exposed to a volunteer's voice vibration testing. Notably, the entire E-Skin fabrication process is scalable, low cost, and industrially available. Our complementary experiments with comprehensive results demonstrate that the developed GNP/PU E-Skin is impressively promising for practical healthcare applications in wearable devices, and enables us to monitor the real-world force signals in real-time and in-situ mode from pressing, hitting, bending, stretching, and voice vibration.

Oriented Arrangement: The Origin of Versatility for Porous Graphene Materials

Macroscopic porous graphene materials composed of graphene sheets have demonstrated their advantageous aspects in diverse application areas. It is essential to maximize their excellent performances by rationally controlling the sheet arrangement and pore structure. Bulk porous graphene materials with oriented pore structure and arrangement of graphene sheets are prepared by marrying electrolyte-assisted self-assembly and shear-force-induced alignment of graphene oxide sheets, and the super elasticity and anisotropic mechanical, electrical, and thermal properties induced by this unique structure are systematically investigated. Its application in pressure sensing exhibits ultrahigh sensitivity of 313.23 kPa^-1 for detecting ultralow pressure variation below 0.5 kPa, and it shows high retention rate for continuously intercepting dye molecules with a high flux of ≈18.7 L m^-2 h^-1 bar^-1 and a dynamic removal rate of 510 mg m^-2 h^-1 .

Binary Synergistic Sensitivity Strengthening of Bioinspired Hierarchical Architectures based on Fragmentized Reduced Graphene Oxide Sponge and Silver Nanoparticles for Strain Sensors and Beyond

Recently, stretchable electronics have been highly desirable in the Internet of Things and electronic skins. Herein, an innovative and cost-efficient strategy is demonstrated to fabricate highly sensitive, stretchable, and conductive strain-sensing platforms inspired by the geometries of a spiders slit organ and a lobsters shell. The electrically conductive composites are fabricated via embedding the 3D percolation networks of fragmentized graphene sponges (FGS) in poly(styrene-block-butadiene-block-styrene) (SBS) matrix, followed by an iterative process of silver precursor absorption and reduction. The slit- and scale-like structures and hybrid conductive blocks of FGS and Ag nanoparticles (NPs) provide the obtained FGS-Ag-NP-embedded composites with superior electrical conductivity of 1521 S cm^-1 , high break elongation of 680%, a wide sensing range of up to 120% strain, high sensitivity of ≈10⁷ at a strain of 120%, fast response time of ≈20 ms, as well as excellent reliability and stability of 2000 cycles. This huge stretchability and sensitivity is attributed to the combination of high stretchability of SBS and the binary synergistic effects of designed FGS architectures and Ag NPs. Moreover, the FGS/SBS/Ag composites can be employed as wearable sensors to detect the modes of finger motions successfully, and patterned conductive interconnects for flexible arrays of light-emitting diodes.

Flexible Sensing Electronics for Wearable/Attachable Health Monitoring

Wearable or attachable health monitoring smart systems are considered to be the next generation of personal portable devices for remote medicine practices. Smart flexible sensing electronics are components crucial in endowing health monitoring systems with the capability of real-time tracking of physiological signals. These signals are closely associated with body conditions, such as heart rate, wrist pulse, body temperature, blood/intraocular pressure and blood/sweat bio-information. Monitoring such physiological signals provides a convenient and non-invasive way for disease diagnoses and health assessments. This Review summarizes the recent progress of flexible sensing electronics for their use in wearable/attachable health monitoring systems. Meanwhile, we present an overview of different materials and configurations for flexible sensors, including piezo-resistive, piezo-electrical, capacitive, and field effect transistor based devices, and analyze the working principles in monitoring physiological signals. In addition, the future perspectives of wearable healthcare systems and the technical demands on their commercialization are briefly discussed.

Flexible and transparent strain sensors based on super-aligned carbon nanotube films

Highly flexible and transparent strain sensors are fabricated by directly coating super-aligned carbon nanotube (SACNT) films on polydimethylsiloxane (PDMS) substrates. The fabrication process is simple, low cost, and favorable for industrial scalability. The SACNT/PDMS strain sensors present a high sensing range of 400%, a fast response of less than 98 ms, and a low creep of 4% at 400% strain. The SACNT/PDMS strain sensors can withstand 5000 stretching-releasing cycles at 400% strain. Moreover, the SACNT/PDMS strain sensors are transparent with 80% transmittance at 550 nm. In situ microscopic observation clarifies that the surface morphology of the SACNT film exhibits a reversible change during the stretching and releasing processes and thus its electrical conductance is able to fully recover to the original value after the loading-unloading cycles. The SACNT/PDMS strain sensors have the advantages of a wide sensing range, fast response, low creep, transparency, and excellent durability, and thus show great potential in wearable devices to monitor fast and large-scale movements without affecting the appearance of the devices.

Simultaneous Detection of Static and Dynamic Signals by a Flexible Sensor Based on 3D Graphene

A flexible acoustic pressure sensor was developed based on the change in electrical resistance of three-dimensional (3D) graphene change under the acoustic waves action. The sensor was constructed by 3D graphene foam (GF) wrapped in flexible polydimethylsiloxane (PDMS). Tuning forks and human physiological tests indicated that the acoustic pressure sensor can sensitively detect the deformation and the acoustic pressure in real time. The results are of significance to the development of graphene-based applications in the field of health monitoring, in vitro diagnostics, advanced therapies, and transient pressure detection.

Harnessing Three Dimensional Anatomy of Graphene Foam to Induce Superior Damping in Hierarchical Polyimide Nanostructures

Graphene foam-based hierarchical polyimide composites with nanoengineered interface are fabricated in this study. Damping behavior of graphene foam is probed for the first time. Multiscale mechanisms contribute to highly impressive damping in graphene foam. Rippling, spring-like interlayer van der Waals interactions and flexing of graphene foam branches are believed to be responsible for damping at the intrinsic, interlayer and anatomical scales, respectively. Merely 1.5 wt% graphene foam addition to the polyimide matrix leads to as high as ≈300% improvement in loss tangent. Graphene nanoplatelets are employed to improve polymer-foam interfacial adhesion by arresting polymer shrinkage during imidization and π-π interactions between nanoplatelets and foam walls. As a result, damping behavior is further improved due to effective stress transfer from the polymer matrix to the foam. Thermo-oxidative stability of these nanocomposites is investigated by exposing the specimens to glass transition temperature of the polyimide (≈400 °C). The composites are found to retain their damping characteristics even after being subjected to such extreme temperature, attesting their suitability in high temperature structural applications. Their unique hierarchical nanostructure provides colossal opportunity to engineer and program material properties.

Formation of large-area stretchable 3D graphene–nickel particle foams and their sensor applications

3D graphene/nickel particles (Gr–NiP) foams, fabricated using CVD and stamp-transfer processes, are used for stretchable sensor applications. The NiP, covered by Gr layers, are useful for the 3D nanostructures and separated from each other for the stretchable application.

Functional Three-Dimensional Graphene/Polymer Composites

Integration of graphene with polymers to construct three-dimensional porous graphene/polymer composites (3DGPCs) has attracted considerable attention in the past few years for both fundamental studies and diverse technological applications. With the broad diversity in molecular structures of graphene and polymers via rich chemical routes, a number of 3DGPCs have been developed with unique structural, electrical, and mechanical properties, chemical tenability, and attractive functions, which greatly expands the research horizon of graphene-based composites. In particular, the properties and functions of the 3DGPCs can be readily tuned by precisely controlling the hierarchical porosity in the 3D graphene architecture as well as the intricate synergistic interactions between graphene and polymers. In this paper, we review the recent progress in 3DGPCs, including their synthetic strategies and potential applications in environmental protection, energy storage, sensors, and conducting composites. Lastly, we will conclude with a brief perspective on the challenges and future opportunities.

Highly Stretchable and Sensitive Strain Sensor Based on Facilely Prepared Three-Dimensional Graphene Foam Composite

Wearable strain sensors with excellent stretchability and sensitivity have emerged as a very promising field which could be used for human motion detection and biomechanical systems, etc. Three-dimensional (3D) graphene foam (GF) has been reported before for high-performance strain sensors, however, some problems such as high cost preparation, low sensitivity, and stretchability still remain. In this paper, we report a highly stretchable and sensitive strain sensor based on 3D GF and polydimethylsiloxane (PDMS) composite. The GF is prepared by assembly process from graphene oxide via a facile and scalable method and possesses excellent mechanical property which facilitates the infiltration of PDMS prepolymer into the graphene framework. The as-prepared strain sensor can be stretched as high as 30% of its original length and the gauge factor of this sensor is as high as 98.66 under 5% of applied strain. Moreover, the strain sensor shows long-term stability in 200 cycles of stretching-relaxing. Implementation of the device for monitoring the bending of elbow and finger results in reproducibility and various responses in the form of resistance change. Thus, the developed strain sensors exhibit great application potential in fields of biomechanical systems and human-interactive applications.

Flexible and printable paper-based strain sensors for wearable and large-area green electronics

Paper-based (PB) green electronics is an emerging and potentially game-changing technology due to ease of recycling/disposal, the economics of manufacture and the applicability to flexible electronics. Herein, new-type printable PB strain sensors (PPBSSs) from graphite glue (graphite powder and methylcellulose) have been fabricated. The graphite glue is exposed to thermal annealing to produce surface micro/nano cracks, which are very sensitive to compressive or tensile strain. The devices exhibit a gauge factor of 804.9, response time of 19.6 ms and strain resolution of 0.038%, all performance indicators attaining and even surpassing most of the recently reported strain sensors. Due to the distinctive sensing properties, flexibility and robustness, the PPBSSs are suitable for monitoring of diverse conditions such as structural strain, vibrational motion, human muscular movements and visual control.

Super-elastic graphene/carbon nanotube aerogels and their application as a strain-gauge sensor

Super-elastic aerogels that exhibit high strain-gauge sensitivities were prepared by integrating CNTs into 3D graphene.

3D Graphene-Infused Polyimide with Enhanced Electrothermal Performance for Long-Term Flexible Space Applications

Polyimides (PIs) have been praised for their high thermal stability, high modulus of elasticity and tensile strength, ease of fabrication, and moldability. They are currently the standard choice for both substrates for flexible electronics and space shielding, as they render high temperature and UV stability and toughness. However, their poor thermal conductivity and completely electrically insulating characteristics have caused other limitations, such as thermal management challenges for flexible high-power electronics and spacecraft electrostatic charging. In order to target these issues, a hybrid of PI with 3D-graphene (3D-C), 3D-C/PI, is developed here. This composite renders extraordinary enhancements of thermal conductivity (one order of magnitude) and electrical conductivity (10 orders of magnitude). It withstands and keeps a stable performance throughout various bending and thermal cycles, as well as the oxidative and aggressive environment of ground-based, simulated space environments. This makes this new hybrid film a suitable material for flexible space applications.

A Stretchable and Highly Sensitive Graphene-Based Fiber for Sensing Tensile Strain, Bending, and Torsion

Wearable sensors are increasingly finding their way into applications of kinesthetic sensing, personal health monitoring, and smart prosthetics/robotics. A graphene-based composite fiber sensor with a "compression spring" structure is fabricated, featuring the ability of detecting multiple kinds of deformation. This fiber sensor is integrated into wearable sensors for monitoring human activities and intricate movements of robotics successfully.

Tuning the Friction Characteristics of Gecko-Inspired Polydimethylsiloxane Micropillar Arrays by Embedding Fe₃O₄ and SiO₂ Particles

In order to improve stiffness of polydimethylsiloxane (PDMS) pillars while maintaining high friction, the effects of embedding Fe3O4 and SiO2 particles on the friction behavior of PDMS micropillars are studied. Both types of added particles increase the stiffness of the PDMS composite, but affect the friction behavior differently. The frictional force of the fibrillar array fabricated with Fe3O4/PDMS composite decreases initially, then increases as the particle content increases. For silica/PDMS composite pillars, the frictional force is independent of the particle density. Characterization by scanning electron microscopy shows that Fe3O4 particles are distributed uniformly in the PDMS matrix at low concentration, but heterogeneous distribution is observed at high particle loading, with particles being hindered from penetrating into the pillars. For silica/PDMS composite pillars, the particles distribute homogeneously inside the pillars, which is attributed to the formation of hydrogen bonding between silica particles and PDMS. The difference in particle distribution behavior is used to explain the observed difference in the friction response of these two composite systems.

Highly stretchable and wearable graphene strain sensors with controllable sensitivity for human motion monitoring

Because of their outstanding electrical and mechanical properties, graphene strain sensors have attracted extensive attention for electronic applications in virtual reality, robotics, medical diagnostics, and healthcare. Although several strain sensors based on graphene have been reported, the stretchability and sensitivity of these sensors remain limited, and also there is a pressing need to develop a practical fabrication process. This paper reports the fabrication and characterization of new types of graphene strain sensors based on stretchable yarns. Highly stretchable, sensitive, and wearable sensors are realized by a layer-by-layer assembly method that is simple, low-cost, scalable, and solution-processable. Because of the yarn structures, these sensors exhibit high stretchability (up to 150%) and versatility, and can detect both large- and small-scale human motions. For this study, wearable electronics are fabricated with implanted sensors that can monitor diverse human motions, including joint movement, phonation, swallowing, and breathing.