Additively manufactured porous elastomeric sensors for simultaneous high-sensitivity pressure detection and wide-dynamic-range motion tracking

Flexible pressure sensors are indispensable components in wearable electronics for health monitoring and exercise management. However, existing pressure sensors face a critical trade-off between high sensitivity and wide detection range. Herein, we present novel flexible pressure sensors based on poly(3,4-ethylenedioxythiophene):poly(styrene sulfonate) (PEDOT:PSS) and thermoplastic polyurethane (TPU), fabricated by direct ink writing (DIW) technology with a sacrificial template strategy. The integration of the high conductivity of PEDOT:PSS, the mechanical durability of TPU, and the engineered hierarchical porous structure with irregular surface topography enables the PEDOT:PSS/TPU-based pressure sensors (PPSs) to achieve an exceptionally wide detection range (0–1044 kPa), high sensitivity (30.178 kPa⁻¹), and outstanding cycling stability (over 10,000 cycles). Leveraging these advantages, the sensors have demonstrated exceptional performance in precise physiological monitoring, effective pressure mapping through sensor arrays, and reliable operation in extreme environments (e.g., cryogenic conditions at −196 °C and underwater). Furthermore, the successful integration with LED circuits and wireless Bluetooth systems highlights their potential for next-generation wearable electronics and personalized healthcare monitoring.