High‐Performance PVA‐PANI‐Fabric Based Pressure Sensors: Enhanced Sensitivity, Durability, and Versatility for Wearable and Smart Interface Applications

ABSTRACT This study presents the development and comprehensive performance evaluation of fabric‐based pressure sensors utilizing polyaniline (PANI) and polyvinyl alcohol‐polyaniline (PVA‐PANI) composites. A custom laboratory setup was employed to analyze sensitivity, retention, dynamic response, repeatability, and long‐term durability under various pressure conditions. Pure PANI sensors exhibited exceptionally high sensitivity (∼50 kPa⁻¹) in the low‐pressure range (0–2 kPa), but performance degraded sharply at higher pressures. In contrast, the PVA‐PANI composite sensors demonstrated a broader operating range and superior mechanical stability, with a peak sensitivity of ∼48 kPa −1 in 0 to 2 kPa and 0.62 kPa⁻¹ in the 2–20 kPa range and consistent ΔR/R retention under sustained and cyclic loading. Both sensors achieved ultrafast response and recovery times (∼0.6 ms), surpassing many reported counterparts. According to the structural analysis, the PVA component improves adhesion, suppresses microcrack formation, and maintains conductivity, accounting for increased long‐term reliability. The PVA‐PANI sensors displayed stable performance over 200 days of durability tests and were successfully integrated into wearable and smart home systems. Applications in walk monitoring and touch interface control demonstrated excellent step detection accuracy, mechanical resilience, and repeatable response behavior under diverse real‐world conditions. These findings establish the PVA‐PANI pressure sensors as strong candidates for next‐generation wearable electronics and intelligent interface technologies.