Flexible piezoresistive sensing device with integrated design and fabrication for health monitoring

Flexible pressure sensors have great potential in medical monitoring, human-computer interaction, and wearable electronics. As a critical component of sensors, the performance of the sensing element is of paramount importance. This study developed an arc-shaped honeycomb piezoresistive sensing element (AHPSE) using Selective Laser Sintering (SLS) technology based on the negative Poisson's ratio effect, which can be used to monitor force during rehabilitation training. The study analyzed AHPSE's sensing mechanism, structural parameters, and piezoresistive performance, establishing a theory for modulus/Poisson's ratio, aiding optimal sensor design. Experimental results showed that compared to traditional sensing element structures, AHPSE exhibited significant improvements in detection range (0.039–2200 kPa), sensitivity (0.029–9.912 kPa⁻¹), response/recovery time (approximately 50 ms and 66 ms), and durability (about 3735 cycles). The structure of this flexible sensing element not only enhances its load-bearing performance but also expands its detection range. This study's flexible sensing element has strong potential in human-computer interaction, physiological monitoring, and medical diagnostics, offering a strategy for manufacturing high-performance, low-cost flexible pressure sensors.