Search Results (38)

Flexible pressure sensors serve as core sensing components for wearable health monitoring systems, electronic skins for soft robots, and flexible human–machine interaction devices. Benefiting from the interfacial electric double-layer polarization effect, iontronic sensing delivers far higher pressure response sensitivity than conventional parallel-plate capacitive sensors, endowing it with distinctive advantages in the detection of weak physiological signals. Nevertheless, current dense ionic thin-film dielectric layers suffer from limited deformation space under compression and poor low-pressure sensing capability. Mainstream high-precision micropillar arrays are fabricated via photolithography, 3D printing, and metal etching molds, which require costly equipment and complicated fabrication procedures, making large-area mass production unfeasible. Random frosted concave-convex microstructures feature disordered dimensions, leading to severe device hysteresis and narrow linear ranges, which fail to achieve ultrahigh sensitivity alongside a wide pressure detection range simultaneously. To address the aforementioned multiple bottlenecks, this paper proposes a low-cost resin template replication process to fabricate TPU-based ionic thin-film dielectric layers with ordered micropillar array microstructures. Combined with inkjet-printed silver conductive PI flexible electrodes, an iontronic flexible pressure sensor with a sandwich layered structure is constructed. Multi-dimensional investigations including microscopic morphology characterization, electromechanical sensing performance calibration, and human wearable application tests are systematically implemented to thoroughly elucidate the synergistic enhancement mechanism of the arrayed micropillars. Test results demonstrate that the effective pressure detection range of the sensor spans 0–1038 kPa, accommodating ultra-low pressures such as pulse signals as well as medium-to-high-pressure loads including joint bending. The sensitivity reaches 23.27 kPa⁻¹ within the low-pressure range of 0–200 kPa and remains stable at 3.52 kPa⁻¹ in the high-pressure range of 200–1038 kPa, with piecewise linear fitting correlation coefficients of 0.93 and 0.96 respectively. Both the response time and recovery time of the device are 40 ms, and the hysteresis error throughout the loading-unloading cycle is merely 2.62%. After 20,000 consecutive cyclic loading-unloading tests, the peak capacitance output only decays by 5.1%, verifying outstanding mechanical fatigue resistance and electrical stability. Validations in multi-scenario applications prove that the sensor can accurately capture human physiological and motion signals including radial artery pulses, laryngeal deformation induced by multi-syllable vocalization, and multi-angle bending of fingers and elbow joints, suitable for home-based health monitoring, quantitative rehabilitation training, flexible tactile interaction and other scenarios. The entire fabrication process eliminates high-precision micro-nano processing equipment such as photolithography systems, plasma etchers and 3D printers; only general chemical raw materials and conventional laboratory instruments are adopted. The reusable templates enable low manufacturing costs and large-area coating forming, offering a novel low-cost technical solution for the engineering implementation and industrialization of high-performance iontronic flexible pressure sensors. Full article

Flexible pressure sensors with porous structures are essential for wearable electronics and robotic perception. However, traditional porous flexible sensors suffer from poor stability and long recovery times. To address these challenges, a strategy integrating bionic architectures inspired by the rigid–flexible coupling structure of Bambusa textilis and the micro-protrusion structure of Salvia plebeia R.Br. is proposed. An aluminum sheet serves as the support layer, and the sensing layer is prepared through mold replication, material impregnation, and layer-by-layer assembly, offering a simple and scalable fabrication route. The sensor exhibits a broad effective pressure range of 0–31.5 kPa, with a minimum resolvable force of 0.2 N, and within its operating range (0–23.5 kPa), the relationship between resistance and pressure exhibits a trend that can be fitted to a quadratic term, with a coefficient of determination of 0.9986. It achieves a minimum response time of 350 ms and maintains stable signals under dynamic loading at different frequencies, indicating reliable detection of low-frequency weak pressures. After 5000 loading–unloading cycles, the device shows no obvious performance degradation. When mounted on a robotic foot, the sensor successfully distinguishes land, sponge, sand, and pebbles surfaces, demonstrating its potential for intelligent environmental perception. Full article

Recently, flexible electronics have attracted widespread attention in personalized health monitoring, soft robotics, and smart human-machine interactions due to intrinsic high stretchability. Among them, constructing buckled structures in flexible devices is one of the most effective strategies to achieve flexibility and stretchability. Flexible electronic devices based on buckled structure (FEDB) have gained significant research progress, owing to their outstanding advantages such as simple fabrication processes, excellent structural stability, and broad applicability. Furthermore, its application areas are expanding to emerging scenarios, including the human body, underwater environments, the oceans, and space. However, there are few systematic reviews concerning their progresses, although researchers show increasing interest in the emerging applications of FEDB. This review summarizes recent research progress in FEDB. First, this review explains the buckled instability mechanism, listing the common conductive and substrate materials. The polymeric substrates discussed mainly include PDMS, TPU, SBS, PC, and hydrogel, which provide the flexibility and deformability required for FEDB. In addition, this review summarizes several methods for constructing buckled structures, including prestretch-release, solvent swelling, thermal, mold, and 3D printing as well as techniques for controlling morphology. Second, this review summarizes the applications of FEDB, such as flexible electrodes, strain and pressure sensors, and energy devices. Particularly, it provides a detailed introduction to the expansion of emerging scenarios, involving underwater monitoring, in vitro and in vivo physiological signal detection, human-machine interactions, and portable capsule devices. Finally, this review points out the current challenges of FEDB, including long-term service stability, adaptability to extreme environments, conformal attachment to complex curved surfaces, and large-scale manufacturing. Full article

Flexible pressure sensors with a porous architecture are highly desirable for wearable health monitoring and intelligent human–machine interaction, owing to their excellent comfort and conformability to human motion. However, conventional porous sensors often suffer from poor signal accuracy and unstable output, which limit their capability for precision sensing. To address these challenges, we designed and fabricated a flexible pressure sensor with exceptional linearity by mimicking the unique surface structure of Iron Cross Begonia (Begonia masoniana) leaves. The sensor is constructed using a readily available melamine foam as the backbone: a porous sensing scaffold is first obtained via a simple dip-coating process, and a film featuring bioinspired protrusions is fabricated by repeated replica molding. Lamination of these two components yields a stacked sensor device. Characterization demonstrates that the sensor achieves a broad pressure detection range of up to 350 kPa, with a minimum resolvable pressure of 250 Pa, and exhibits an excellent linearity of 0.999 over its entire working range (0–350 kPa). Moreover, the sensor shows stable responses under varying loading frequencies, is capable of detecting low-frequency signals, and retains its performance without notable degradation even after 5000 repeated loading-unloading cycles. In practical applications, the sensor accurately monitors flexion and extension movements of the wrist, finger, neck, and knee, capturing human motion signals with high fidelity. Furthermore, it enables information encoding and transmission through finger gestures. The proposed bioinspired structural design strategy effectively enhances the overall performance of porous pressure sensors, offering a new paradigm for the development of flexible sensing devices with promising applications in wearable health monitoring, human motion detection, and human–machine interaction. Full article

Resolving the dichotomy between wide detection ranges and low mechanical hysteresis remains a critical challenge in flexible electronics, largely governed by the intrinsic viscoelastic creep of polymeric dielectrics. Drawing inspiration from the distinctive load-bearing mechanisms of traditional Chinese Sparrow Brace architecture, we report a mechanically optimized tilted micro-architecture designed to enhance structural resilience. Unlike conventional soft elastomeric pillars that easily succumb to mechanical failure, this BOPS-based tilted geometry provides excellent load-bearing capacity, effectively preventing premature failure. Finite element analysis (FEA) confirms that this tilted geometry forces a fundamental shift from conventional bulk compression to structural bending. Because this bending-dominated architecture drives rapid elastic recovery, it significantly mitigates the severe effects of the polymer’s viscoelastic creep under the tested loading conditions, achieving reliable signal reversibility with low hysteresis. We fabricated this specific architecture via programmable femtosecond laser direct writing (FsLDW) on biaxially oriented polystyrene (BOPS) films, harnessing the material’s entropy-driven self-growth kinetics. By merging this localized growth mechanism with the architectural design, we effectively bypassed the complexities of traditional molding, achieving mask-free, in situ growth of large-scale, highly uniform dielectric micro-arrays. The resulting sensor delivers a remarkably broad working range (up to ~2.28 MPa) coupled with a negligible recovery error (~1.3%), an agile dynamic response (~70/80 ms), and consistent operational durability. Ultimately, this work combines architecture-inspired structural design with advanced femtosecond laser surface microengineering, providing a conceptually novel and scalable pathway for next-generation flexible sensing. Full article

Sensitivity and effective sensing range are core performance metrics of flexible pressure sensors, directly dictating their practical applicability. A key challenge in sensor design is sensitivity degradation with elevated pressure, hindering synergistic optimization of high sensitivity and broad sensing range, while cumbersome electrode fabrication further impedes facile preparation and large-scale deployment of high-performance devices. Herein, this work proposes a novel fabrication strategy for flexible iontronic pressure sensors via direct laser writing (DLW) technology. A controllable ultraviolet laser patterns polyimide substrates to fabricate hierarchical stepped conoid-like microstructural templates, which are transferred to ion gels through reverse molding. The DLW-enabled precise geometric control and hierarchical conical architectures efficiently amplify interfacial contact area variation under pressure, significantly boosting sensitivity. The resultant sensor achieves a high sensitivity of 118.4 kPa⁻¹ and a broad detection range up to 2000 kPa, with fast response/recovery times of 38.4 ms and 47 ms and excellent mechanical stability enduring 2000 loading–unloading cycles at 850 kPa. Multi-scenario physiological signal monitoring validates its accurate capture of laryngeal vibrations and joint movements. This work establishes a straightforward, efficient microfabrication route for high-performance flexible iontronic sensors, accelerating their practical application in wearable health monitoring and related fields. Full article

Solid rocket motors (SRMs) play a pivotal role in space exploration owing to their reliability and high thrust-to-weight ratios. SRM propellant health monitoring is in critical demand owing to the complex operational scenarios throughout the entire life cycle of SRMs. To achieve in situ detection of three-dimensional stress, this study introduces a novel flexible three-dimensional stress sensor (FSS). First, a liquid metal pressure-sensing element with a variable cross-section was designed and numerically modeled. The performance of the FSS under different loading conditions was analyzed using finite element modeling. The sensing element prototype was fabricated using mold casting and liquid metal injection methods. The fabricated sensing-element prototype with an area ratio of 1:5 exhibited a sensitivity coefficient of 1.5%/kPa at a pressure of 300 kPa, a maximum hysteresis error of 3.98%, and a stability error of 0.17%. Finally, the FSS was developed by integrating multiple pressure-sensing elements and encapsulating the force-concentrating layers. The fabricated FSS prototype was characterized using simulated propellant experiments. Via comparison with the simulation results, the FSS was found to detect multiaxial stress differences when embedded within a propellant. Full article

At present, high-resolution and reliable inductive sensors have increasingly emerged as a pivotal component in the advancement of flexible electronic devices. The integration of liquid metal with flexible substrates presents a promising approach for the fabrication of inductive sensors. This paper introduces a novel paperclip-type helical coil inductive sensor, characterized by advancements in both structural design and a simplified manufacturing process. The sensor comprises a fine silicone tube filled with liquid metal, encapsulated within polydimethylsiloxane (PDMS) glue. A significant innovation of this design is its complete elimination of the need for high-precision sacrificial metal molds. This approach bypasses complex processes such as precision mold machining, demolding, and post-mold residue cleaning, thereby significantly streamlining the production work-flow. We optimized the parameters of the paperclip-type helical coil, the aspect ratio, and the number of turns, achieving the maximum sensitivity under limited conditions. Experimental results demonstrate that this sensor is capable of tensile, pressure, and non-contact distance sensing. The linearity of the tensile sensing is exceptional ($R^2=0.999$), with consistent performance observed after 800 tensile cycles. The pressure sensing range extends from 0 to 230 kPa, and the non-contact distance sensing is effective within a range of 10 mm. Furthermore, the sensor exhibits strong performance in monitoring human physiological activities and metal distance detection, demonstrating significant application potential in flexible electronics and wearable devices. Full article

Soft manipulators have garnered significant research attention in recent years due to their flexibility and adaptability. However, the inherent flexibility of these manipulators imposes limitations on their load-bearing capacity and stability. To address this, this study compares various variable stiffness technologies and proposes a novel design concept: leveraging the phase-change characteristics of low-melting-point alloys (LMPAs) with distinct melting points to fulfill the variable stiffness requirements of soft manipulators. The pneumatic structure of the manipulator is fabricated via 3D-printed molds and silicone casting. The manipulator integrates a pneumatic working chamber, variable stiffness chambers, heating devices, sensors, and a central channel, achieving multi-stage variable stiffness through controlled heating of the LMPAs. A steady-state temperature field distribution model is established based on the integral form of Fourier’s law, complemented by finite element analysis (FEA). Subsequently, the operational temperatures at which the variable stiffness mechanism activates, and the bending performance are experimentally validated. Finally, stiffness characterization and kinematic performance experiments are conducted to evaluate the manipulator’s variable stiffness capabilities and flexibility. This design enables the manipulator to switch among low, medium, and high stiffness levels, balancing flexibility and stability, and provides a new paradigm for the design of soft manipulators. Full article

In this study, we present a flexible piezoelectric nanogenerator based on a zinc oxide (ZnO)/polyvinylidene fluoride (PVDF) nanocomposite electrospun onto a hemisphere-patterned PDMS substrate. The nanogenerator was fabricated by replicating a silicon mold with inverted hemispheres into PDMS, followed by direct electrospinning of ZnO-dispersed PVDF nanofibers. Varying the ZnO concentration from 0.6 to 1.4 wt% allowed us to evaluate its effect on structural, dielectric, and piezoelectric properties. The nanogenerator containing 0.8 wt% ZnO exhibited the thinnest fibers (371 nm), the highest β-phase fraction (85.6%), and the highest dielectric constant (35.8). As a result, it achieved the maximum output voltage of 7.30 V, with excellent signal consistency under an applied pressure of 5 N. Comparisons with pristine PVDF- and ZnO/PVDF-only devices demonstrated the synergistic effect of ZnO loading and patterned PDMS on the enhancement of piezoelectric output. The hemisphere-patterned PDMS substrate improved the mechanical strain distribution, interfacial contact, and charge collection efficiency. These results highlight the potential of ZnO/PVDF/PDMS hybrid nanogenerators for use in wearable electronics and self-powered sensor systems. Full article

We report a new concept of a pressure sensor fully made from polydimethylsiloxane with a solid core and porous cladding that operates through (frustrated) total internal reflection. A flexible and sensitive rectangular cross-section waveguide was fabricated via the casting and molding method. The waveguide’s optical losses can be temperature-controlled during the fabrication process by controlling the quantity of microbubbles incorporated (2% approximately for samples made at 70 °C). By controlling the precuring temperature, the microbubbles are incorporated into the waveguides during the simple and cost-effective fabrication process through the casting and molding method. For these samples, we measured good optical loss tradeoff of the order of 1.85 dB/cm, which means that it is possible to fabricate a solid-core/clad waveguide with porous cladding able to guide light properly. We demonstrated the microbubble concentration control in the waveguide, and we measured an average diameter of 239 ± 16 µm. A sensitivity to pressure of 0.1035 dB/kPa optical power loss was measured. The results show that in a biomedical dynamic pressure range (0 to 13.3 kPa), this new device indicates the critical pressure threshold level, which constitutes a crucial asset for potential applications such as pressure injury prevention. Full article

Glove-based human–machine interfaces (HMIs) offer a natural, intuitive way to capture finger motions for gesture recognition, virtual interaction, and robotic control. However, many existing systems suffer from complex fabrication, limited sensitivity, and reliance on external power. Here, we present a flexible, self-powered glove HMI based on a minimalist triboelectric nanogenerator (TENG) sensor composed of a conductive fabric electrode and textured Ecoflex layer. Surface micro-structuring via 3D-printed molds enhances triboelectric performance without added complexity, achieving a peak power density of 75.02 μW/cm² and stable operation over 13,000 cycles. The glove system enables real-time LED brightness control via finger-bending kinematics and supports intelligent recognition applications. A convolutional neural network (CNN) achieves 99.2% accuracy in user identification and 97.0% in object classification. By combining energy autonomy, mechanical simplicity, and machine learning capabilities, this work advances scalable, multi-functional HMIs for applications in assistive robotics, augmented reality (AR)/(virtual reality) VR environments, and secure interactive systems. Full article

The Fe-36Ni alloy, with ultra-low thermal expansion and stable properties, is essential for aerospace remote sensors and aircraft load-bearing structures, widely used in aerospace. Additive Manufacturing, an emerging rapid prototyping technology with short cycles, high efficiency, and flexibility, addresses complex structural fabrication challenges. While selective laser melting (SLM) enables complex geometry fabrication, post-process treatments (e.g., annealing-induced homogenization, thermal aging for stress relief, surface polishing) remain critical for attaining metallurgical stability in as-built components. The impact of different laser scanning speeds (500 mm/s, 1000 mm/s, 1500 mm/s, 2000 mm/s) on the microstructure and mechanical and thermal expansion properties of the Fe-36Ni alloy fabricated by selective laser melting was studied. The results indicate that all Fe-36Ni alloys predominantly exhibit the γ-phase. Interestingly, a small amount of α precipitates was also observed, which is primarily attributed to the formation of a supercooled region. Notably, at a scanning speed of 1000 mm/s, the Fe-36Ni alloy samples exhibit optimal mechanical properties, with a tensile strength of 439 MPa and an elongation of 49.0%. This improvement is primarily attributed to the enhanced molding quality and grain refinement. The minimum coefficient of thermal expansion occurs at a scanning speed of 2000 mm/s, likely due to the elevated defect density. Full article

The rapid development of flexible sensor technology has made flexible sensor arrays a key research area in various applications due to their exceptional flexibility, wearability, and large-area-sensing capabilities. These arrays can precisely monitor physical parameters like pressure and strain in complex environments, making them highly beneficial for sectors such as smart wearables, robotic tactile sensing, health monitoring, and flexible electronics. This paper reviews the fabrication processes, operational principles, and common materials used in flexible sensors, explores the application of different materials, and outlines two conventional preparation methods. It also presents real-world examples of large-area pressure and strain sensor arrays. Fabrication techniques include 3D printing, screen printing, laser etching, magnetron sputtering, and molding, each influencing sensor performance in different ways. Flexible sensors typically operate based on resistive and capacitive mechanisms, with their structural designs (e.g., sandwich and fork-finger) affecting integration, recovery, and processing complexity. The careful selection of materials—especially substrates, electrodes, and sensing materials—is crucial for sensor efficacy. Despite significant progress in design and application, challenges remain, particularly in mass production, wireless integration, real-time data processing, and long-term stability. To improve mass production feasibility, optimizing fabrication processes, reducing material costs, and incorporating automated production lines are essential for scalability and defect reduction. For wireless integration, enhancing energy efficiency through low-power communication protocols and addressing signal interference and stability are critical for seamless operation. Real-time data processing requires innovative solutions such as edge computing and machine learning algorithms, ensuring low-latency, high-accuracy data interpretation while preserving the flexibility of sensor arrays. Finally, ensuring long-term stability and environmental adaptability demands new materials and protective coatings to withstand harsh conditions. Ongoing research and development are crucial to overcoming these challenges, ensuring that flexible sensor arrays meet the needs of diverse applications while remaining cost-effective and reliable. Full article

Hydrogels with excellent flexibility, conductivity, and controllable mechanical properties are the current research hotspots in the field of biomaterial sensors. However, it is difficult for hydrogel sensors to regain their original function after being damaged, which limits their practical applications. Herein, a composite hydrogel (named SPBC) of poly(vinyl alcohol) (PVA)/sodium alginate (SA)/cellulose nanofibers (CNFs)/sodium borate tetrahydrate was synthesized, which has good self-healing, electrical conductivity, and excellent mechanical properties. The SPBC0.3 hydrogel demonstrates rapid self-healing (<30 s) and achieves mechanical properties of 33.92 kPa. Additionally, it exhibits high tensile strain performance (4000%). The abundant internal ions and functional groups of SPBC hydrogels provide support for the good electrical conductivity (0.62 S/cm) and electrical response properties. In addition, the SPBC hydrogel can be attached to surfaces such as fingers and wrists to monitor human movements in real time, and its good rheological property supports three-dimensional (3D) printing molding methods. In summary, this study successfully prepared a self-healing, conductive, printable, and mechanically superior SPBC hydrogel. Its suitability for 3D-printing personalized fabrication and outstanding sensor properties makes it a useful reference for hydrogels in wearable devices and human motion monitoring. Full article