Stretchable elastomer composites with segregated filler networks: effect of carbon nanofiller dimensionality

Carbon-Based Piezoresistive Polymer Nanocomposites by Extrusion Additive Manufacturing: Process, Material Design, and Current Progress

Advancement in additive manufacturing (AM) allows the production of nanocomposites with complex and custom geometries not typically allowable with conventional manufacturing techniques. The benefits of AM have led to recent interest in producing multifunctional materials capable of being printed with current AM technologies. In this article, piezoresistive composites realized by AM and the matrices and fillers utilized to make such devices are introduced and discussed. Carbon-based nanoparticles (Carbon Nanotubes, Graphene/Graphite, and Carbon Black) are often the filler choice of most researchers and are heavily discussed throughout this review in combination with extrusion AM methods. Piezoresistive applications such as physiological and wearable sensors, structural health monitoring, and soft robotics are presented with an emphasis on material and AM selection to meet the demands of such applications.

Biomimetic Flexible Sensors and Their Applications in Human Health Detection

Bionic flexible sensors are a new type of biosensor with high sensitivity, selectivity, stability, and reliability to achieve detection in complex natural and physiological environments. They provide efficient, energy-saving and convenient applications in medical monitoring and diagnosis, environmental monitoring, and detection and identification. Combining sensor devices with flexible substrates to imitate flexible structures in living organisms, thus enabling the detection of various physiological signals, has become a hot topic of interest. In the field of human health detection, the application of bionic flexible sensors is flourishing and will evolve into patient-centric diagnosis and treatment in the future of healthcare. In this review, we provide an up-to-date overview of bionic flexible devices for human health detection applications and a comprehensive summary of the research progress and potential of flexible sensors. First, we evaluate the working mechanisms of different classes of bionic flexible sensors, describing the selection and fabrication of bionic flexible materials and their excellent electrochemical properties; then, we introduce some interesting applications for monitoring physical, electrophysiological, chemical, and biological signals according to more segmented health fields (e.g., medical diagnosis, rehabilitation assistance, and sports monitoring). We conclude with a summary of the advantages of current results and the challenges and possible future developments.

Thermally Drawn Elastomer Nanocomposites for Soft Mechanical Sensors

Stretchable and conductive nanocomposites are emerging as important constituents of soft mechanical sensors for health monitoring, human-machine interactions, and soft robotics. However, tuning the materials' properties and sensor structures to the targeted mode and range of mechanical stimulation is limited by current fabrication approaches, particularly in scalable polymer melt techniques. Here, thermoplastic elastomer-based nanocomposites are engineered and novel rheological requirements are proposed for their compatibility with fiber processing technologies, yielding meters-long, soft, and highly versatile stretchable fiber devices. Based on microstructural changes in the nanofiller arrangement, the resistivity of the nanocomposite is tailored in its final device architecture across an entire order of magnitude as well as its sensitivity to strain via tuning thermal drawing processing parameters alone. Moreover, the prescribed electrical properties are coupled with suitable device designs and several fiber-based sensors are proposed aimed at specific types of deformations: i) a robotic fiber with an integrated bending mechanism where changes as small as 5° are monitored by piezoresistive nanocomposite elements, ii) a pressure-sensing fiber based on a geometrically controlled resistive signal that responds with a sub-newton resolution to changes in pressing forces, and iii) a strain-sensing fiber that tracks changes in capacitance up to 100% elongation.

Direct Ink Writing for High-Efficiency Microwave Attenuation with Nanofibers Alignment

One-dimensional (1D) fibers have been widely used in composites reinforcement for microwave attenuation due to their outstanding mechanical and electromagnetic properties, especially in the axial direction. However, the precise control of fiber alignment in a polymer matrix remains a challenge. In this work, we successfully demonstrated the well-controlled alignment of silicon carbide nanowires (SiCNW) in a silicone matrix by using direct ink writing (DIW)-based 3D printing. It is proven that the printed multilayer material with fiber alignment could show a dramatic improvement in both reflection loss (RL) and effective attenuation bandwidth (EAB, RL < -10 dB). In particular, a uniaxial in-plane orientation is found to be the optimal alignment among other planar and also out-of-plane orientations. Benefiting from the optimized alignment, the 3D-printed SiC composite could show an EAB (∼6.4 GHz)1.6 times broader than that of the randomly mixed composite at the same thickness without alignment, associated with a minimum RL of -48 dB at 14.3 GHz. In addition, it is demonstrated that DIW could print different materials, such as SiCNW and multiwall carbon nanotube (MWCNT), in alternating layers for multiple-frequency-band attenuation benefiting from the distinct property of each material. Considering the one-step control of fiber alignment and material selectivity, DIW could play an important role in materials design for high-efficiency microwave attenuation.

Durability Study of Thermal Transfer Printed Textile Electrodes for Wearable Electronic Applications

Textile-based electronics hold great promise because they can endow wearable devices with soft and comfortable characteristics. However, the inherent porosity and fluffiness of fabrics result in high surface roughness, which presents great challenges in the manufacture of high-performance fabric electrodes. In this work, we propose a thermal transfer printing method to address the above challenges, in which electrodes or circuits of silver flake/thermoplastic polyurethane (TPU) composites are prefabricated on a release film by coating and laser engraving and then laminated by hot-pressing to a variety of fabrics and textiles. This universal and scalable production technique enables fabric electrodes to be made without compromising the original wearability, washability, and stretchability of textiles. The prepared fabric electrodes exhibit high conductivity (5.48 × 10⁴ S/cm), high adhesion (≥1750 N/m), good abrasion/washing resistance, high patterning resolution (∼40 μm), and good electromechanical performance up to 50% strain. To demonstrate the potential applications, we developed textile-based radio frequency identification (RFID) tags for remote identification and a large-sized heater for wearable thermotherapy. More importantly, the solvent-free thermal transfer printing technology developed in this paper enables people to DIY interesting flexible electronics on clothes with daily tools, which can promote the commercial application of smart textile-based electronics.

Facile Fabrication of Highly Sensitive Thermoplastic Polyurethane Sensors with Surface- and Interface-Impregnated 3D Conductive Networks

This research aims to develop a practical, scalable, and highly conductive flexible 3D printed piezoresistive sensor with low filler content. Here, we introduced a fused deposition modeling 3D printing combined in situ spray-coating technique to develop a conductive sensor in a single shot. The graphene suspension is sprayed over each layer during the 3D printing of the sensor, which helps develop a conductive network on the surface and at the interface of the printed system. Graphene deposited on the overall surface is often affected by nanoparticle delamination and loses its function over time. To avoid this, the prepared samples are subjected to foaming. The foaming process created a low-mass-density sensor by forming a microcellular structure, and the surface-deposited graphene is embedded well on the TPU surface. The method followed in this work reveals a stable and connected conduction path with excellent electrical resistance and resistance against harsh conditions (exposure to organic solvents). Besides, the compression sensor withstood its sensitivity over a severe compressive strain of 80% and showed a GF of 1.82 and a sensitivity of 2.316 kPa^-1. The conductive network path varied based on the infill pattern, affecting its electrical sensitivity. The wiggle pattern shows good resistance; under stretching, the pattern generated a higher current and showed a delayed conductive path disconnection than other patterns. Thus, the embedded graphene/TPU conductive sensors show good stability and promising sensitivity. Furthermore, the developed sensor is used to monitor human motion and actions.

Recent Advances in Multiresponsive Flexible Sensors towards E-skin: A Delicate Design for Versatile Sensing

Multiresponsive flexile sensors with strain, temperature, humidity, and other sensing abilities serving as real electronic skin (e-skin) have manifested great application potential in flexible electronics, artificial intelligence (AI), and Internet of Things (IoT). Although numerous flexible sensors with sole sensing function have already been reported since the concept of e-skin, that mimics the sensing features of human skin, was proposed about a decade ago, the ones with more sensing capacities as new emergences are urgently demanded. However, highly integrated and highly sensitive flexible sensors with multiresponsive functions are becoming a big thrust for the detection of human body motions, physiological signals (e.g., skin temperature, blood pressure, electrocardiograms (ECG), electromyograms (EMG), sweat, etc.) and environmental stimuli (e.g., light, magnetic field, volatile organic compounds (VOCs)), which are vital to real-time and all-round human health monitoring and management. Herein, this review summarizes the design, manufacturing, and application of multiresponsive flexible sensors and presents the future challenges of fabricating these sensors for the next-generation e-skin and wearable electronics.

Electrically Conductive Silicone-Based Nanocomposites Incorporated with Carbon Nanotubes and Silver Nanowires for Stretchable Electrodes

Stretchable electrode materials have attracted great attention as next-generation electronic materials because of their ability to maintain intrinsic properties with rare damage when undergoing repetitive deformations, such as folding, twisting, and stretching. In this study, an electrically conductive PDMS nanocomposite was manufactured by combining the hybrid nanofillers of carbon nanotubes (CNTs) and silver nanowires (AgNWs). The amphiphilic isopropyl alcohol molecules temporarily adhered simultaneously to the hydrophobic CNT and hydrophilic AgNW surfaces, thereby improving the dispersity. As the CNT/AgNW ratio (wt %/wt %) decreased under the constant nanofiller content, the tensile modulus decreased and the elongation at break increased owing to the poor interaction between the AgNWs and matrix. The shear storage moduli of all nanocomposites were higher than the loss moduli, indicating the elastic behavior with a cross-linked network. The electrical conductivities of the nanocomposite containing the hybrid nanofillers were superior to those of the nanocomposite containing either CNT or AgNW at the same filler content (4 wt %). The hybrid nanofillers were rearranged and deformed by 5000 cyclic strain tests, relaxing the PDMS matrix chain and weakening the interfacial bonding. However, the elastic behavior was maintained. The dynamic electrical conductivities gradually increased under the cyclic strain tests due to the rearrangement and tunneling effect of the nanofillers. The highest dynamic electrical conductivity (10 S/m) was obtained for the nanocomposite consisting of 2 wt % of CNTs and 2 wt % of AgNWs.

Highly Sensitive Ultrathin Flexible Thermoplastic Polyurethane/Carbon Black Fibrous Film Strain Sensor with Adjustable Scaffold Networks

In recently years, high-performance wearable strain sensors have attracted great attention in academic and industrial. Herein, a conductive polymer composite of electrospun thermoplastic polyurethane (TPU) fibrous film matrix-embedded carbon black (CB) particles with adjustable scaffold network was fabricated for high-sensitive strain sensor. This work indicated the influence of stereoscopic scaffold network structure built under various rotating speeds of collection device in electrospinning process on the electrical response of TPU/CB strain sensor. This structure makes the sensor exhibit combined characters of high sensitivity under stretching strain (gauge factor of 8962.7 at 155% strain), fast response time (60 ms), outstanding stability and durability (> 10,000 cycles) and a widely workable stretching range (0-160%). This high-performance, wearable, flexible strain sensor has a broad vision of application such as intelligent terminals, electrical skins, voice measurement and human motion monitoring. Moreover, a theoretical approach was used to analyze mechanical property and a model based on tunneling theory was modified to describe the relative change of resistance upon the applied strain. Meanwhile, two equations based from this model were first proposed and offered an effective but simple approach to analyze the change of number of conductive paths and distance of adjacent conductive particles.

Advances in Materials for Soft Stretchable Conductors and Their Behavior under Mechanical Deformation

Soft stretchable sensors rely on polymers that not only withstand large deformations while retaining functionality but also allow for ease of application to couple with the body to capture subtle physiological signals. They have been applied towards motion detection and healthcare monitoring and can be integrated into multifunctional sensing platforms for enhanced human machine interface. Most advances in sensor development, however, have been aimed towards active materials where nearly all approaches rely on a silicone-based substrate for mechanical stability and stretchability. While silicone use has been advantageous in academic settings, conventional silicones cannot offer self-healing capability and can suffer from manufacturing limitations. This review aims to cover recent advances made in polymer materials for soft stretchable conductors. New developments in substrate materials that are compliant and stretchable but also contain self-healing properties and self-adhesive capabilities are desirable for the mechanical improvement of stretchable electronics. We focus on materials for stretchable conductors and explore how mechanical deformation impacts their performance, summarizing active and substrate materials, sensor performance criteria, and applications.

Design Strategy for Porous Composites Aimed at Pressure Sensor Application

Flexible and highly sensitive pressure sensors have versatile biomedical engineering applications for disease diagnosis and healthcare. The fabrication of such sensors based on porous structure composites usually requires complex, costly, and nonenvironmentally friendly procedures. As such, it is highly desired to develop facile, economical, and environment-friendly fabrication strategies for highly sensitive lightweight pressure sensors. Herein, a novel design strategy is reported to fabricate porous composite pressure sensors via a simple heat molding of conductive fillers and thermoplastic polyurethane (TPU) powders together with commercially available popcorn salts followed by water-assisted salt removal. The obtained TPU/carbon nanostructure (CNS) foam sensors have a linear resistance response up to 60% compressive strain with a gauge factor (G_F ) of 1.5 and show reversible and reproducible piezoresistive properties due to the robust electrically conductive pathways formed on the foam struts. Such foam sensors can be potentially utilized for guiding squatting exercises and respiration rate monitoring in daily physical training.

Soft elastomeric composite materials with skin-inspired mechanical properties for stretchable electronic circuits

The stretchable version of electronic circuits harnesses commercial chip scale components to achieve complex functionality and mechanical deformability, which represents an emerging technology to expand the application of conventional electronics on rigid wafers. The bottleneck lies in the lack of a robust approach for the collective integration of off-the-shelf components into a reliable system. In this study, an elastomeric composite material with skin-like mechanical responses and spatially heterogeneous rigidity is reported as an attractive platform for stretchable circuit systems. The approach utilizes a high modulus microstructure embedded in the matrix of a soft elastomer to achieve programmable mechanical properties, thereby offering selective strain isolation for fragile components and overall protection against excessive loads. A low cost procedure involving laser ablation and blade coating is established to create the composite material matching with the circuit design. In addition, ultrasonic atomization of liquid metal into microparticles allows flexible preparations of deformable conductors in the forms of interconnects and contacts. An LED matrix is demonstrated as a prototype circuit system with excellent durability to withstand repetitive stretching and external impacts. Stretchable circuit systems based on soft elastomeric composite materials may find potential uses in health monitoring, mechatronic prosthetics, and soft robotics.