Search Results (272)

Flexible strain sensors, fabricated from high-elongation polymers and conductive filler particles, are proving an essential tool in the study of biomechanics using wearable technology. It has been previously shown that the resistive response of such composites, relative to the amount of conductive filler material, can be reasonably modeled using a standard percolation-type model. Once a certain critical fraction of filler material is reached, a conductive network across the sample is established and resistance rapidly decreases. However, modeling the more subtle resistance changes that occur while deforming the sensors during operation is more nuanced. Conductivity across the network of particles is dominated by tunneling mechanisms at the interfaces between the filler materials. Small changes in strain at these interfaces lead to relatively large, but nevertheless continuous, changes in local resistance. By assigning some arbitrary value of resistance as a dividing line between ‘low’ and ‘high’ resistance, one might model the piezoresistive behavior using a standard percolation model. But such an assumption is likely to lead to low accuracy. Our alternative approach is to divide the range of potential resistance values into several bins (rather than the usual two bins) and apply a relatively novel multi-state percolation theory. The performance of the multi-state percolation model is assessed using a random resistor model that is assumed to provide the ground truth. The model is applied to predict resistance response with both changes in relative amount of conductive filler (i.e., to help design the initial unstrained sensor) and with applied strain (for an operating sensor). We find that a multi-state percolation model captures the behavior of the simulated composite sensor in both cases. The multicomponent percolation theory becomes more accurate with more divisions/bins of the resistance distribution, and we found good agreement with the simulation using between 10 and 20 divisions. Full article

Polyurethane (PU) foam, renowned for its structural versatility, elasticity, compressibility, and adaptability, has garnered significant attention for its use in flexible strain sensors due to its capability to detect mechanical deformation. This review presents a comprehensive analysis of both the studies and recent advancements in PU foam-based strain sensors, particularly those incorporating conductive materials. The review begins by examining the chemical composition and structural characteristics of PU foam, followed by a discussion of various fabrication methods and their effects on sensor performance. It also explores the sensing mechanisms, including piezoresistive, piezoelectric, and capacitive effects. Moreover, key applications in motion detection, health monitoring, and environmental and industrial sensing are examined. Finally, the review addresses technological advancements, current challenges, and prospects. Full article

Fibrous structure is a promising building block for developing high-performance wearable piezoresistive sensors. However, the inherent non-conductivity of the fibrous polymer remains a bottleneck for highly sensitive and fast-responsive piezoresistive sensors. Herein, we reported a polyaniline/reduced graphene oxide @ polydopamine/poly (vinylidene fluoride) (PANI/rGO@PDA/PVDF) nanofiber piezoresistive sensor (PNPS) capable of versatile wearable biomonitoring. The PNPS was fabricated by integrating rGO sheets and PANI particles into a PDA-modified PVDF nanofiber network, where PDA was implemented to boost the interaction between the nanofiber networks and functional materials, PANI particles were deposited on a nanofiber substrate to construct electroactive nanofibers, and rGO sheets were utilized to interconnect nanofibers to strengthen in-plane charge carrier transport. Benefitting from the synergistic effect of multi-dimensional electroactive materials in piezoresistive membranes, the as-fabricated PNPS exhibits a high sensitivity of 13.43 kPa⁻¹ and a fast response time of 9 ms, which are significantly superior to those without an rGO sheet. Additionally, a wide pressure detection range from 0 to 30 kPa and great mechanical reliability over 12,000 cycles were attained. Furthermore, the as-prepared PNPS demonstrated the capability to detect radial arterial pulses, subtle limb motions, and diverse respiratory patterns, highlighting its potential for wearable biomonitoring and healthcare assessment. Full article

A flexible and highly sensitive piezoresistive strain sensor was fabricated through the application of CO₂ laser ablation on a composite film composed of multi-walled carbon nanotubes, carbon black, and polydimethylsiloxane (MWCNT/CB/PDMS). The results of scanning electron microscopy (SEM) surface analysis shows that the “bush-like” conductive structure on the PDMS-based composite material membrane post-laser ablation is formed. Transmission electron microscopy (TEM) images and X-ray diffraction (XRD) spectra of the ablation products indicated the formation of an amorphous carbon layer on the surface of carbon nanomaterials due to laser ablation. Experimental findings revealed that the sensitivity (GF) value of the sensor based on CNT0.6CB1.0-P3.0 is up to 584.7 at 5% strain, which is approximately 14% higher than the sensitivity 513 of the sensor previously prepared by the author using CO₂ laser ablation of MWCNT/PDMS composite films. The addition of a very small volume fraction of CB particles significantly enhances the piezoresistive sensitivity of the sensor samples. Combined with the qualitative analysis of microscopic morphology characterization, CB and MWCNT synergistically promote the deposition of amorphous carbon. This phenomenon increases the probability of tunnel effect occurrence in the strain response region of the sensor, which indirectly confirms the synergistic enhancement effect of the combined action of CB and MWCNT on the piezoresistive sensitivity of the sensor. Full article

Carbon nanotubes (CNTs) have emerged as pivotal nanomaterials in sensing technologies owing to their unique structural, electrical, and mechanical properties. Their high aspect ratio, exceptional surface area, excellent electrical conductivity, and chemical tunability enable superior sensitivity and rapid response in various sensor platforms. This review presents a comprehensive overview of recent advancements in CNT-based sensors, encompassing both single-walled (SWCNTs) and multi-walled carbon nanotubes (MWCNTs). We discuss their functional roles in diverse sensing applications, including gas sensing, chemical detection, biosensing, and pressure/strain monitoring. Particular emphasis is placed on the mechanisms of sensing, such as changes in electrical conductivity, surface adsorption phenomena, molecular recognition, and piezoresistive effects. Furthermore, we explore strategies for enhancing sensitivity and selectivity through surface functionalization, hybrid material integration, and nanostructuring. The manuscript also covers the challenges of reproducibility, selectivity, and scalability that hinder commercial deployment. In addition, emerging directions such as flexible and wearable CNT-based sensors, and their role in real-time environmental, biomedical, and structural health monitoring systems, are critically analyzed. By outlining both current progress and existing limitations, this review underscores the transformative potential of CNTs in the design of next-generation sensing technologies across interdisciplinary domains. Full article

Monitoring posture and movement accurately and efficiently is essential for both physical therapy and athletic training evaluation and interventions. Motion Tape (MT), a self-adhesive wearable skin-strain sensor made of piezoresistive graphene nanosheets (GNS), has demonstrated promise in capturing low back posture and movements. However, to address some of its limitations, this work explores alternative materials by replacing GNS with multi-walled carbon nanotubes (MWCNT). This study aimed to characterize the electromechanical properties of MWCNT-based MT. Cyclic load tests for different peak tensile strains ranging from 1% to 10% were performed on MWCNT-MT made with an aqueous ink of 2% MWCNT. Additional tests to examine load rate sensitivity and fatigue were also conducted. After characterizing the properties of MWCNT-MT, a human subject study with 10 participants was designed to test its ability to capture different postures and movements. Sets of six sensors were made from each material (GNS and MWCNT) and applied in pairs at three levels along each side of the lumbar spine. To record movement of the lower back, all participants performed forward flexion, left and right bending, and left and right rotation movements. The results showed that MWCNT-MT exceeded GNS-MT with respect to consistency of signal stability even when strain limits were surpassed. In addition, both types of MT could assess lower back movements. Full article

The additive manufacturing of piezoresistive sensors offers several advantages, such as the elimination of assembly or installation steps, enabling integration into complex parts precisely where desired, and compatibility with soft robotics applications. Previous studies have demonstrated that several characteristics of additively manufactured sensors, such as their resistance and sensitivity, are significantly affected by the selected printing parameters. This work seeks to further the understanding of the relationships between process parameters, material, sensor design, and the resulting sensor characteristics. To this end, sensors made from two materials, with differing printing layer heights, infill angles, and thicknesses, are characterized under cyclic tensile loading. For these sensors, the nonlinearity, hysteresis, and drift are analyzed. The findings indicate that both nonlinearity and hysteresis are significantly affected by the material choice, as well as the selected parameters. Notably, parameters that affect the sensitivity of the sensor, e.g., the infill angle, can have significant indirect effects on the nonlinearity and hysteresis errors. Through correct parameter selection, nonlinearity errors can be reduced by up to 30.7% or 25.3%, depending on the material used. The hysteresis error can be reduced by up to 38.7% or 23.8%, depending on the material. The drift over multiple cycles is found to be strongly material dependent, but can also be affected by the process parameters, e.g., the infill angle. Understanding the interactions between material, design, process, and the resulting sensor characteristics provides valuable insights for the successful design and additive manufacturing of piezoresistive sensors. Full article

Smart cement-based materials have the potential to monitor the health of structures. The performances of composites with various kinds of conductive fillers have been found to be sensitive and stable. However, poor dispersion of conductive fillers limits their application. This study adopted the coupling agent method to attach carbon nanotubes (CNTs) onto the surface of carbon fibers (CFs). The CNT-grafted CFs (CNT-CFs) were adopted as conductive fillers to develop a CNT-CF-incorporated cementitious composite (CNT-CF/CC). The feasibility of this approach was demonstrated through Scanning Electron Microscopy (SEM) analysis and X-ray Photoelectron Spectroscopy (XPS) analysis. The CNT-CF/CC exhibited excellent conductivity because of the introduction of CNTs compared with the CF-incorporated cementitious composite (CF/CC). The CNT-CF/CC reflected huge responses under different temperatures and moisture contents. Even under conditions of high humidity or elevated temperatures, the CNT-CF/CC demonstrated stable performance and exhibited a broad measurement range. The introduction of CNT-CFs also enhanced the mechanical properties of the composite, displaying superior piezoresistivity. The failure load for the CNT-CF/CC reached 25 kN and the maximum FCR was 24.77%. In the cyclic loading, the maximum FCR reached 20.03% when subjected to peak cyclic load at 45% of the failure load. The additional conductive pathways introduced by CNTs enhanced the conductivity and sensitivity of the composite. And the anchoring connection between CNT-CFs and the cement matrix has been identified as a primary factor enhancing the stability in performance. Full article

Vibration sensors are important in many engineering fields, including industry, surgery, space, and mechanics, such as for remote and autonomous driving. We propose a novel, cutting-edge vibratory sensor that mimics human tactile receptors, with a configuration different from current sensors such as strain gauges and piezo materials. The basic principle involves the perception of vibration via touch, with a cutaneous mechanoreceptor that is sensitive to vibration. We investigated the characteristics of the proposed vibratory sensor, in which the mechanoreceptor was covered either in hard rubber (such as silicon oil) or soft rubber (such as urethane), for both low- and high-frequency ranges. The fabricated sensor is based on piezoelectricity with a built-in voltage. It senses applied vibration by means of hairs in the sensor and the hardness of the outer cover. We also investigated two proposed parameters: the sensor response time to stimuli to the vibration aiding the equivalent firing rate (e.f.r.) and the gauge factor (GF_,pe) proposed as treated in piezo-resistivity. The evaluation with the parameters was effective in designing a sensor based on piezoelectricity. These parameters were enhanced by the hairs in the sensor and the hardness of the outer cover. Our results were helpful for designing the present novel vibratory sensor. Full article

In recent years, flexible pressure sensors have attracted significant attention due to their extensive application prospects in wearable devices, healthcare monitoring, and other fields. Herein, we propose a flexible piezoresistive sensor with a broad detection range, utilizing a CNT/PVA composite as the pressure-sensitive layer. The effect of the CNT-to-PVA ratio on sensing performance was systematically investigated, revealing that the sensor’s sensitivity initially increases and then decreases with rising CNT content. When the weight percentage of CNTs reaches 11.24 wt%, the sensing film exhibits optimal piezoresistive properties. A resistance model of the composite conductive material was established to elucidate the sensing mechanism associated with CNT content in detail. Furthermore, hill-like microstructures were fabricated on a PDMS substrate using sandpaper as a template to further enhance overall performance. The sensor demonstrates a sensitivity of 0.1377 kPa⁻¹ (<90 kPa), a sensing range of up to 400 kPa, a response time of 160 ms, and maintains excellent stability after 2000 folding cycles. It can accurately detect human joint flexion and muscle activity. This work is expected to provide a feasible solution for flexible electronic devices applied in human motion monitoring and analysis, particularly offering competitive advantages in applications involving wide-range pressure detection. Full article

In recent years, flexible piezoresistive sensors based on polydimethylsiloxane (PDMS) matrix materials have developed rapidly, showing broad application prospects in fields such as human motion monitoring, electronic skin, and intelligent robotics. However, achieving a balance between structural durability and fabrication simplicity remains challenging. Traditional methods for preparing PDMS flexible substrates with high porosity and high stability often require complex, costly processes. Breaking through the constraints of conventional material systems, this study innovatively combines the high elasticity of polydimethylsiloxane (PDMS) with the stochastically distributed porous topology of a sponge-derived biotemplate through biomimetic templating replication technology, fabricating a heterogeneous composite system with an architecturally asymmetric spatial network. After 5000 loading cycles, uncoated samples experienced a thickness reduction of 7.0 mm, while PDMS-coated samples showed minimal thickness changes (2.0–3.0 mm), positively correlated with curing agent content (5:1 to 20:1). The 5:1 ratio sample demonstrated exceptional mechanical stability. As evidenced, the PDMS film-encapsulated architecturally asymmetric spatial network demonstrates superior stress dissipation efficacy, effectively mitigating stress concentration phenomena inherent to symmetric configurations that induce matrix fracture, thereby achieving optimal mechanical stability. Compared to the pre-test resistance distribution of 10–248 Ω, after 5000 cyclic loading cycles, the uncoated samples exhibited a narrowed resistance range of 10–50 Ω, while PDMS-coated samples maintained a broader resistance range (10–240 Ω) as the curing agent ratio increased (from 20:1 to 5:1), demonstrating that increasing the curing agent ratio helps maintain conductive network stability. The 5:1 ratio sample displayed the lowest resistance variation rate attenuation—only 3% after 5000 cycles (vs. 80% for uncoated samples)—and consistently minimal attenuation at all stages, validating superior electrical stability. Under 0–6 kPa pressure, the 5:1 ratio device maintained a linear sensitivity of 0.157 kPa⁻¹, outperforming some existing works. Human motion monitoring experiments further confirmed its reliable signal output. Furthermore, the architecturally asymmetric spatial network of the device enables superior conformability to complex curvilinear geometries, leveraging its structural anisotropy to achieve seamless interfacial adaptation. By synergistically optimizing material composition and structural design, this study provides a novel technical method for developing highly durable flexible electronic devices. Full article

Flexible piezoresistive pressure sensors have great potential in wearable electronics due to their simple structure, low cost, and ease of fabrication. Porous polymer materials, with their highly deformable internal pores, effectively expand the sensing range. However, a single-sized pore structure struggles to achieve both high sensitivity and a broad sensing range simultaneously. In this study, a PDMS-based flexible pressure sensor with a bilayer porous structure (BLPS) was successfully fabricated using clamping compression and a sacrificial template method with spherical sucrose cores. The resulting sensor exhibits highly uniform pore sizes, thereby improving performance consistency. Furthermore, since different pore sizes and thicknesses correspond to varying Young’s moduli, this study achieves tunable sensitivity across a wide pressure range by adjusting the bilayer thickness ratio (maximum sensitivity of $0.063 {\mathrm{kPa}}^{-1}$ in the 0–23.6 kPa range, with a pressure response range of 0–654 kPa). The sensor also demonstrates a fast response time (128 ms) and excellent fatigue stability (>10,000 cycles). Additionally, this sensor holds great application potential for facial expression monitoring, joint motion detection, pressure distribution matrices, and Morse code communication. Full article

The present article investigates the effect of superplasticizer and graphene nanoplatelet addition on the flexural and electrical behaviour of nanocomposites for applications related to the restoration/conservation of Cultural Heritage Monuments in laboratory scale. Graphene nanoplatelets’ addition is used to transform the matrix into a piezo-resistive self-sensor by efficiently dispersing electrically conductive graphene nanoplatelets (GnPs) in the material matrix to create electrically conductive paths. Nevertheless, the appropriate dispersion is difficult to be achieved as the GnPs tend to agglomerate due to Van der Waals forces. To this end, the effect of the addition of carboxyl-based superplasticizer (SP) is proposed in the present investigation to efficiently disperse the GnPs in the water mix of the binders. Five (5) different ratios of SP per GnPs addition were examined. The GnPs concentration was chosen to be within the range of 0.05 to 1.50 wt.% of the binder. The same ultrasonic energy was applied in all of the suspensions to further aid the dispersion process. The incorporation of graphene nanoplatelets at low concentrations (0.15 wt.%) significantly increases flexural strength when added in equal quantity to superplasticizer (SP1 series). The SP addition at higher concentrations does not enhance the mechanical properties through effective dispersion of the GnPs. Additionally, a correlation was established between the electrical resistivity (ρ) values of the produced nanocomposites and the modulus of elasticity as a function of the GnPs concentration. The functional correlation between these parameters was also confirmed by linear regression analysis, resulting from the experimental data fitting. Finally, the acoustic emission (AE) can effectively capture damage evolution in such lime-based composites, while the emitted cumulative energy rises as the GnPs concentration is increased. Full article

In the present work, we provide the development results of highly efficient conductive biopolymer composite films with potential use as piezoresistive sensors. Natural isotactic biopolymer poly(3-hydroxybutyrate-co-3-hydroxyvalerate) (PHBV) was selected as the primary biopolymer material. To reduce the crystallinity and improve the processability of PHBV, the synthetic atactic (R,S)poly-3-hydroxybutyrate ((R,S)-PHB) polyester was blended with the semicrystalline PHBV biopolyester. Graphene nanomaterials with different structures, comprising crude multi-walled carbon nanotubes (MWCNTs), oxidatively functionalized multi-walled carbon nanotubes (ox-MWCNTs) and graphene nanoplatelets (GNPs), were proposed as electroactive fillers. The preparation of the composites was based on a simplified solvent casting method and the conductive graphene fillers were dispersed into the biopolyester matrix without any further routines. As a result of the optimization, a PHBV/((R,S)-PHB) mass ratio of 70:30 was found to be the most promising composition to obtain composite films with the expected mechanical characteristics. The influence of graphene filler structure on the degree of crystallinity, viscoelastic, electrical, and piezoresistive properties obtained for of the composites was determined. The lowest PHBV/PHB matrix crystallinities of 37% (DSC) and 39% (XRD) were recorded for the composite with 1% ox-MWCNTs and 1% GNPs. The most promising piezoresistive responses were noted for composites filled simultaneously with 1% GNPs and 1% ox-MWCNTs or MWCNTs. However, a 1.5% deformation and recovery did not affect the initial conductivity of the PHBV/(R,S)-PHB +1%MWCNTs+1%GNP system (9 × 10⁻⁵ S/cm), while for the system with oxidized carbon nanotubes, the resistance increases by approximately 0.2% in relation to the initial value (8 × 10⁻⁶ S/cm). Full article

In recent years, there has been a growing interest in and research efforts enabling the use of composite conductive 3D-printing filaments in material extrusion additive manufacturing processes, which can bestow novel and distinctive functions onto 3D-printed components. These composite filaments, in general blending a thermoplastic with carbon-based materials, open up new research and development avenues in electronics and sensors. Additionally, by exploring the underlying piezoresistivity of conductive filaments, they also enable the creation of novel structural components possessing integrated (intrinsic) self-sensing capabilities that can be effectively employed in structural health monitoring of critical components. However, piezoresistivity features require measuring the electrical resistance of structures made with these conductive filaments, which might be hard, especially when measuring small changes in resistance caused by mechanical loads on the component. The goal of this study is to compare the two- and four-probe methods for measuring the electrical resistance of 3D-printed parts and to look at how different types of electrical contacts and bonding may affect electrical resistivity measurement and self-sensing capabilities. The research is conducted on 3D-printed specimens using a conductive composite PLA (polylactic acid) filament from Protopasta. The efficiency of each method and the influence of the bonding and electrodes on the measurements are experimentally analyzed and discussed. Our experiments reveal that the four-probe method consistently yields resistivity values between 15.35 and 16.38 $\mathrm{\Omega }·$cm, while the two-probe method produces significantly higher values (up to 52.92–62.37 $\mathrm{\Omega }·$cm), underscoring the impact of wire and contact resistances on measurement accuracy. Full article