Scalable Self-Sensing Mechanical Metamaterials by Conformal Coating of 3D-Printed Lattices with Nanocomposites

Metamaterials possess unique and desirable multiphysical behaviors derived from deliberately arranging conventional materials into designed structural topologies. Multifunctional mechanical metamaterials that can both carry load and provide in situ state awareness are increasingly needed for applications such as structural health monitoring and soft robotic systems. To address the demand for multifunctional metamaterials, this study reports a scalable fabrication strategy for self-sensing lattice metamaterials by conformally dip-coating 3D-printed flexible cells with a carbon nanotube (CNT)-styrene-ethylene-butylene-styrene (SEBS) nanocomposite. Scanning electron microscopy shows that the coating conforms closely to the printed struts with well-dispersed CNT networks. The electromechanical behavior of coated Octet, Kelvin, and auxetic unit cells was characterized under quasi-static cyclic uniaxial compression (0-40% strain). All the coated structures exhibited highly stable, reversible, and repeatable piezoresistive response, with a near-linear relationship between resistance change and strain. Among the tested geometries, the auxetic unit cell achieved the highest strain sensitivity that was approximately four times that of the Octet cell and six times that of the Kelvin cell. To evaluate scalability, auxetic lattices containing eight scaled auxetic unit cells were shown to retain high sensitivity and remained statistically similar to the unit cell. This study demonstrates that the strain sensing performance of nanocomposites can be engineered through lattice topology using a simple dip-coating functionalization approach, enabling scalable self-sensing metamaterials for large-scale and conformal sensing applications.