The development of highly sensitive magnetic field sensors is critical for applications in biomedical diagnostics, wearable technologies, and environmental monitoring. While conventional research focuses on material composition, the influence of geometric configuration remains largely unexplored. This study demonstrates the profound impact of macroscopic shape on the sensitivity of magnetorheological (MR) nanocomposite sensors. Initial macroscopic experiments with pyramid-like structures revealed unexpected localized magnetic field perturbations, challenging the assumption that only material properties dictate field interactions. Inspired by these findings, we fabricated a novel optical fiber magnetic field sensor using magnetic nanoparticles dispersed within a polydimethylsiloxane (PDMS) matrix. The sensor's performance was evaluated by subjecting it to a controlled harmonic magnetic field using a neodymium magnet. Our comparative analysis revealed that a conventional spherical sensor had a limited sensitivity of 0.0065 pm/mT and a resolution of ∼ 2mT. In contrast, an innovatively designed pyramidal sensor exhibited a remarkable sensitivity of 35.098 pm/µT, achieving a resolution of ∼ 0.2 µT. This represents a groundbreaking enhancement of over 5 million times in sensitivity and an improvement of nearly four orders of magnitude in resolution. We attribute this unprecedented amplification to the geometrical concentration of magnetic flux within the pyramidal shape, a finding that highlights the critical role of macroscopic geometry in dictating the performance of advanced sensing platforms and presents a promising pathway for the development of next-generation, ultrasensitive magnetic field detectors in different industrial and bio medical applications.
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