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Flexible and Anisotropic Large-Area Piezoresistive Films for High Spatial Resolution Pressure Mapping.

Nagarpita Moka Vidyanag1, Jesse Grant1, Jeffery Dahl2

  • 1School of Materials Engineering, Birck Nanotechnology Center, Purdue University, West Lafayette, Indiana 47907, United States.

ACS Applied Materials & Interfaces
|June 7, 2025
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Summary

This study developed a flexible, large-area pressure sensor using a novel roll-to-roll process. The sensor offers high resolution and reliability for applications like automotive occupant detection systems.

Keywords:
anisotropicflexiblepiezoresistivepressure sensorspatial-pressure mapping

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Area of Science:

  • Materials Science
  • Sensor Technology
  • Nanotechnology

Background:

  • Advanced technologies require reliable, high-resolution pressure sensors for surface conformability and spatial force measurement.
  • Applications include automotive occupant detection systems (ODSs), wearable biometric and monitoring systems (BMS), and human-machine interfaces (HMIs).

Purpose of the Study:

  • To develop a flexible, large-area piezoresistive sensor using a scalable roll-to-roll process.
  • To evaluate the sensor's electromechanical properties, performance under various conditions, and spatial mapping capabilities.

Main Methods:

  • Fabrication of a flexible sensor using a roll-to-roll process with an anisotropic conductive film of nickel microcolumns in a silicone matrix.
  • Electromechanical testing under uniaxial compression to determine stress range and tunability.
  • CO2 laser ablation to optimize interfacial contact resistance.
  • Strain rate and cyclic loading tests to assess dynamic performance and reliability.
  • Design of a 15 cm × 15 cm sensor array with 100 sensing points and a multiplexed readout system.

Main Results:

  • The sensor demonstrated tunability for operation up to 1.2 MPa stress range.
  • CO2 laser ablation enhanced sensor performance by optimizing contact resistance.
  • The unique microcolumnar morphology minimized electrical crosstalk, enabling high-resolution spatial mapping.
  • The sensor showed stability under dynamic conditions and robust performance over 100 cycles.
  • A 15 cm × 15 cm sensor array with 100 sensing points achieved high-resolution spatial mapping.

Conclusions:

  • The developed flexible, large-area piezoresistive sensor offers high sensitivity, a broad operational range, and excellent mechanical reliability.
  • The roll-to-roll fabrication process enables scalable production.
  • This technology provides a foundation for high-performance, high-resolution flexible pressure sensors in advanced applications.