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Vol. 17 (2025)

Flexible Strain Sensors with Ultra-High Sensitivity and Wide Range Enabled by Crack-Modulated Electrical Pathways

https://doi.org/10.1007/s40820-024-01571-6
Yunzhao Bai
State Key Laboratory of Intelligent Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan 430074, People’s Republic of China
Yunlei Zhou
Hangzhou Institute of Technology, Xidian University, Hangzhou 311200, People’s Republic of China
Xuanyu Wu
State Key Laboratory of Intelligent Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan 430074, People’s Republic of China
Mengfei Yin
State Key Laboratory of Intelligent Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan 430074, People’s Republic of China
Liting Yin
Department of Aerospace and Mechanical Engineering, University of Southern California, Los Angeles, CA 90089, USA
Shiyuan Qu
State Key Laboratory of Intelligent Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan 430074, People’s Republic of China
Fan Zhang
State Key Laboratory of Intelligent Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan 430074, People’s Republic of China
Kan Li
State Key Laboratory of Intelligent Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan 430074, People’s Republic of China
YongAn Huang
State Key Laboratory of Intelligent Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan 430074, People’s Republic of China

Corresponding Author: YongAn Huang

yahuang@hust.edu.cn

Nano-Micro Letters, Vol. 17 (2025), Article Number: 64

Abstract

This study presents a breakthrough in flexible strain sensor technology with the development of an ultra-high sensitivity and wide-range sensor, addressing the critical challenge of reconciling sensitivity with measurement range. Inspired by the structure of bamboo slips, we introduce a novel approach that utilises liquid metal to modulate the electrical pathways within a cracked platinum fabric electrode. The resulting sensor demonstrates a gauge factor greater than 108 and a strain measurement capability exceeding 100%. The integration of patterned liquid metal enables customisable tuning of the sensor’s response, while the porous fabric structure ensures superior comfort and air permeability for the wearer. Our design not only optimises the sensor’s performance but also enhances the electrical stability that is essential for practical applications. Through systematic investigation, we reveal the intrinsic mechanisms governing the sensor’s response, offering valuable insights for the design of wearable strain sensors. The sensor’s exceptional performance across a spectrum of applications, from micro-strain to large-strain detection, highlights its potential for a wide range of real-world uses, demonstrating a significant advancement in the field of flexible electronics.


Highlights:
1 A method is proposed for the modulation of electrical pathways in the cracks of stretchable electrodes using liquid metals, based on which ultra-high sensitivity (> 108) and large-range (> 100%) strain sensors are realised.
2 A secondary modulation of the response (or performance) of the sensor is proposed, allowing not only electrical modulation by liquid metal patterning during fabrication, but also mechanical modulation by pre-stretching at the time of use.
3 The air permeability and stability of the patterned liquid metal electrode region is optimised to enable air permeability similar to that of conventional fabrics and cycle durability in excess of 2000 cycles.

Keywords

Flexible strain sensor Fabric Crack Response regulation Epidermal device
Bai, Yunzhao, Yunlei Zhou, Xuanyu Wu, Mengfei Yin, Liting Yin, Shiyuan Qu, Fan Zhang, Kan Li, and YongAn Huang. 2024. “Flexible Strain Sensors With Ultra-High Sensitivity and Wide Range Enabled by Crack-Modulated Electrical Pathways”. Nano-Micro Letters 17 (November):64. https://doi.org/10.1007/s40820-024-01571-6.
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