The development of high-performance elastic conductive yarns is often constrained by a formidable challenge: the inherent trade-off between high sensitivity and a wide sensing range, rooted in the poor adhesion and catastrophic fracture of conductive coatings upon stretching. Herein, we report a novel subsurface engineering strategy facilitated by an in-situ constructed FeOOH nanoscaffold on polyurethane (PU) yarns, which, combined with a pre-stretching design, effectively guides the distribution of polypyrrole (PPy) during polymerization. The process parameters were optimized via an orthogonal experimental design, which successfully constructs a strain-adaptive hierarchical conductive network characterized by surface microcracks, interfacial folded structures, and an internal PPy-permeated layer. The optimized conductive yarn exhibits an exceptional combination of an ultra-high gauge factor (3.71 × 106) and a wide sensing range (up to 310 % strain). Mechanistic investigations reveal that the electrical response adapts to strain through a smart transition of the dominant conductive pathway: from surface crack propagation at low strains (ensuring high sensitivity) to the continuous internal network at large strains (guaranteeing broad range and durability). The FeOOH scaffold is proven crucial for enhancing the coating's uniformity and firmness. Finally, we demonstrate the practical utility of our sensor in monitoring diverse human motions and subtle physiological signals, showcasing its potential as a high-performance platform for wearable health monitoring.
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