Fabrication and performance of 3D-printed bidirectional cantilever sensors

Abstract

3D-printed conductive thermoplastic polyurethane (TPU) sensors are attracting significant global interest for their potential application in advanced health monitoring. However, the development of bidirectional sensors with enhanced stretchability and bidirectional sensing performance remains a critical challenge worldwide. This short communication research addresses this challenge by proposing a novel fabrication approach: utilizing TPU as the base substrate, coupled with a Fused Deposition Modeling (FDM) printed layer and a graphene drop coating as the sensitive layer. The integration of TPU/graphene with a PEDOT: PSS dip coat was implemented to augment sensitivity and conductivity accumulation across diverse bending directions. The resulting sensor exhibits high stretchability, with the embedded graphene (Gr) modulating conductivity and sensitivity in response to bidirectional deformations. These deformations are accurately detected through piezoresistive behaviors, offering superior sensitivity to conventional sensors for mechanical deformation detection in both directions. Ultimately, FDM printing with composite materials enables the development of highly customizable and functional cantilever sensors, driving innovation in next-generation wearable and health monitoring technologies.