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Highly Sensitive Anisotropic Multidirectional Strain Sensor through Direct-Write Micro-3D Printing Ordered

Mengjie Wang1, Dongliang Zhang1, Yifan Jiang1

  • 1Shandong Engineering Research Center for Additive Manufacturing, Qingdao University of Technology, Qingdao 266520, China.

ACS Applied Materials & Interfaces
|August 27, 2025
PubMed
Summary

A novel micro-3D printing method creates highly ordered microfibers for advanced multidirectional strain sensors. This breakthrough enhances sensitivity and selectivity for precise motion detection in flexible electronics.

Keywords:
airflow field-drivenhighly ordered microfiberhighly sensitivemicro-3D printingmultidirectional strain sensors

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Area of Science:

  • Materials Science
  • Flexible Electronics
  • Sensor Technology

Background:

  • Multidirectional strain sensors are crucial for flexible electronics but face challenges in achieving anisotropy for precise movement detection.
  • Current methods struggle to balance high sensitivity and selectivity, hindering the differentiation of axial strains.

Purpose of the Study:

  • To develop a micro-3D printing approach for fabricating highly ordered microfibers.
  • To enable direct printing of orthogonally aligned microfibers for precise in-plane strain direction identification.
  • To create a streamlined, integrated process for producing multidirectional strain sensors.

Main Methods:

  • Utilized micro-three-dimensional (3D) printing to fabricate highly ordered microfibers.
  • Combined Polylactic acid (PLA) and Polybutylene adipate-co-terephthalate (PBAT) in a 75:25 ratio.
  • Automated control of microfiber alignment and spacing during the printing process.

Main Results:

  • Achieved significant anisotropy in sensor response (sensitivity ratio of 541:2.12) and high selectivity (11.98).
  • Demonstrated excellent performance: 44% operating range, maximum gauge factor (GF) of 541, durability over 500 cycles, low detection limit (2% strain), and fast response (210 ms).
  • Successfully distinguished between strains of different directions and magnitudes.

Conclusions:

  • The micro-3D printing approach efficiently resolves the trade-off between high directional selectivity and sensitivity in multidirectional strain sensors.
  • The integrated preparation of cross-affecting highly ordered fibers shows significant potential for human-machine motion detection and wearable electronics.