Force sensors (FSs) in caregiving and rehabilitation applications need to be lightweight, flexible and capable of adapting within dynamic environments. Therefore, by leveraging the unique thermo-responsive stiffness-tunable properties of shape-memory polymer (SMP), we previously proposed FSs with variable sensitivity and measuring range by taking advantage of stiffness change, structural modification and programming in cross-sectional area. In this work, we have combined the concept of our preliminarily developed FS and presented a novel structure of the adaptable polyurethane SMP-FS consisting of center and flap sections. We have employed inbuilt titanium wires to heat the sensor above the glass transition temperature ( = 45 °C) and soften it, allowing us to change the bending shape automatically. A steel shim plate is also bonded to the center section for attaching a strain gauge. The notable difference in the slope of the “Force vs. deformation and strain” profile, as determined by linear regression at both the initial and bent positions and above and below , indicates that the sensitivity of this FS can be varied by adjusting its cross-section and stiffness. The experimental measurements positively demonstrate about 3.3 times improvement in sensitivity for our proposed prototype at modified cross-sectional state than the initial shape. Several other critical performance metrics like hysteresis, non-linearity, and long-term stability (slope and baseline strain drift) are also presented and quantified at all configurations (ORIGIN, BENT 1, BENT 2) and temperatures. They are found to have within acceptable limit for soft sensing field. Furthermore, we have theoretically validated the experimental data by implementing finite element analysis of the SMP-FS geometries. The evidence observed from the trend of deformation responses and change in sensitivities both at below and above have suggested acceptable accuracy of our experimental approach.
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