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Robotic Drop-Coating Graphite-Copper PDMS Soft Pressure Sensor with Fabric-Integrated Electrodes for Wearable

Zeping Yu1, Yunhao Zhang1, Lingpu Ge2

  • 1Graduate School of Computer Science and Engineering, University of Aizu, Aizuwakamatsu 965-8580, Japan.

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|November 27, 2025
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Summary

A novel robotic drop-coating method fabricates advanced graphite-copper nanoparticle/Polydimethylsiloxane (PDMS) flexible pressure sensors. This scalable technique enhances conductivity and integration for wearable electronics and soft robotics.

Keywords:
PDMS compositeflexible pressure sensorgraphite–copper nanoparticleshuman–machine interactionrobotic drop-coatingtextile-integrated electrodeswearable devices

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Area of Science:

  • Materials Science
  • Nanotechnology
  • Robotics

Background:

  • Flexible pressure sensors are crucial for wearable tech, human-machine interfaces, and soft robotics.
  • Conventional Polydimethylsiloxane (PDMS)-based sensors face challenges like poor conductivity, filler dispersion, and textile integration.

Purpose of the Study:

  • To develop a scalable fabrication method for high-performance flexible pressure sensors.
  • To overcome limitations of traditional PDMS-based sensor manufacturing.

Main Methods:

  • Utilized a robotic drop-coating technique for precise deposition of graphite-copper nanoparticle (G-CuNP)/PDMS composites.
  • Fabricated a three-layer sandwiched structure with textile-integrated electrodes.
  • Systematically investigated filler loading and G-CuNP ratios, optimizing at 40 wt% total fillers (55 wt% graphite).

Main Results:

  • Achieved high sensitivity in low-pressure regions and stable performance in medium-to-high pressure ranges (R² = 0.998).
  • Demonstrated excellent cyclic stability (>1000 cycles) with 7.42% average hysteresis.
  • Successfully mapped multipoint forces using a hand-shaped sensor matrix, distinguishing grasping behaviors.

Conclusions:

  • Robotic drop-coating offers a scalable and advantageous approach for fabricating advanced flexible pressure sensors.
  • The developed G-CuNP/PDMS sensors present a promising solution for low-cost, reliable wearable applications.