Superhydrophobic flexible sensors: A review of fabrication methods and applications

Flexible sensors have garnered extensive application in fields such as smart wearables , biomedical devices , and industrial production owing to their exceptional flexibility and high sensitivity. However, in complex environments (e.g., underwater, humid, acidic/alkaline conditions), conventional flexible sensors face significant technical bottlenecks, including susceptibility to signal interference and surface corrosion , severely limiting their long-term stability and reliability. Superhydrophobic surfaces, characterized by their unique wettability properties, offer an innovative solution to these challenges. By endowing flexible sensors with self-cleaning, low-adhesion, corrosion resistance , and anti-interference capabilities, superhydrophobicity significantly enhances their applicability in harsh environments. This review systematically summarizes recent advances in superhydrophobic flexible sensors. Initially, the limitations of conventional flexible sensors in practical applications are introduced. Subsequently, the theoretical foundations of superhydrophobic surface wettability and the types/characteristics of flexible sensors are presented. Furthermore, diverse fabrication strategies for superhydrophobic flexible sensors are critically discussed, encompassing techniques such as spraying, dip-coating, sandwich structure design, and laser etching, with a systematic evaluation of their respective advantages and disadvantages. Additionally, the innovative applications of these sensors in three major domains—smart wearables, vibration monitoring , and gas detection—are analyzed. Finally, the review identifies current shortcomings in fabrication technologies and outlines prospective future research directions, serving as a valuable reference for understanding the latest developments and applications of superhydrophobic flexible sensors. • The current development status of the intersection of superhydrophobic surfaces and flexible sensors. • Advantages and disadvantages of different process preparation methods for superhydrophobic flexible sensors. • The application of superhydrophobic flexible sensors in smart wearable devices, industrial vibration monitoring and harmful gas monitoring fields. • The current problems with superhydrophobic flexible sensors and their future development directions.