Aerodynamic‐Invisibility Stretchable Pressure Sensor Array for High‐Speed Ground and Air Vehicles

ABSTRACT Accurate surface‐pressure mapping is crucial for aerodynamic optimization of high‐speed ground and air vehicles. However, existing air‐pressure‐sensing technologies cannot simultaneously achieve large‐area coverage, conformability to non‐developable surfaces, aerodynamic invisibility, and non‐invasiveness. Here, we present a stretchable, aerodynamic‐invisibility pressure‐sensor array that overcomes these limitations. This array integrates a 4 × 4 grid of miniaturized pressure sensors connected by stretchable multilayer serpentine interconnects that accommodate 30% strain, enabling conformal, non‐invasive deployment on complex surfaces. Owing to a non‐buckling interconnect design (thickness‐to‐width ratio of ∼0.55) that minimizes out‐of‐plane deformation, the array maintains a total thickness below ∼1.6 mm, remaining thin relative to the flow boundary layer and thus minimizing aerodynamic disturbance. Tests on a scale model of the Chinese standard electric multiple unit 3 (EMU‐3) in a moving train model system demonstrate accurate, spatially resolved surface‐pressure mapping consistent with numerical simulations, highlighting its great potential for aerodynamic testing and optimization in high‐speed vehicles.