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Programmable direct-patterning assembly enables high-density and surface-conformal integration of fiber Bragg grating
Yin Tao1,2, Wen Xu1,2, Peishi Yu3,4
1Jiangsu Key Laboratory of Advanced Food Manufacturing Equipment and Technology, School of Mechanical Engineering, Jiangnan University, Wuxi, PR China.
Nature Communications
|May 4, 2026
Summary
This study introduces a direct-fiber-Bragg-grating (FBG) patterning method for precise, high-density sensor integration on curved surfaces. This programmable assembly overcomes manual limitations for advanced aerospace and manufacturing applications.
Area of Science:
- Materials Science
- Optoelectronics
- Mechanical Engineering
Background:
- Fiber Bragg grating (FBG) sensors offer high sensitivity for aerospace and manufacturing but manual assembly limits precision and integration density.
- Current deployment methods struggle with conformality on complex surfaces and under extreme conditions.
Purpose of the Study:
- To develop a programmable direct-FBG-patterning (DFP) paradigm for one-step integration of FBG arrays.
- To enable precise, high-density, and conformal sensor deployment on arbitrary curved and non-developable surfaces.
Main Methods:
- A mechanics-optics coupled framework was developed to identify minimum bending radii based on interfacial debonding, fiber fracture, and optical attenuation.
- Cross-fiber routing and conformal assembly strategies were employed for high-density sensor networks along a single continuous fiber.
Main Results:
- The DFP paradigm enables one-step integration of multiplexed FBG arrays onto complex surfaces.
- Minimum bending radii were defined, governing achievable feature size and multidirectional sensing capabilities.
- High-density sensor networks were achieved, surpassing manual assembly limitations.
Conclusions:
- The DFP assembly paradigm offers a general strategy for quasi-distributed sensing beyond manual assembly constraints.
- Demonstrated robust FBG sensor integration for structural displacement, phonation, and gesture monitoring.
- This approach enhances precision, integration density, and conformality for FBG sensor deployment.
