Wearable and Flexible Sensor Devices: Recent Advances in Designs, Fabrication Methods, and Applications

The development of wearable sensor devices brings significant benefits to patients by offering real-time healthcare via wireless body area networks (WBANs). These wearable devices have gained significant traction due to advantageous features, including their lightweight nature, comfortable feel, stretchability, flexibility, low power consumption, and cost-effectiveness. Wearable devices play a pivotal role in healthcare, defence, sports, health monitoring, disease detection, and subject tracking. However, the irregular nature of the human body poses a significant challenge in the design of such wearable systems. This manuscript provides a comprehensive review of recent advancements in wearable and flexible smart sensor devices that can support the next generation of such sensor devices. Further, the development of direct ink writing (DIW) and direct writing (DW) methods has revolutionised new high-resolution integrated smart structures, enabling the design of next-generation soft, flexible, and stretchable wearable sensor devices. Recognising the importance of keeping academia and industry informed about cutting-edge technology and time-efficient fabrication tools, this manuscript also provides a thorough overview of the latest progress in various fabrication methods for wearable sensor devices utilised in WBAN and their evaluation using body phantoms. An overview of emerging challenges and future research directions is also discussed in the conclusion.