Geometry-engineered hourglass-shaped cracks enable wide-linearity wearable strain sensors

Flexible and stretchable strain sensors have attracted growing interest for applications in health monitoring and human-machine interfaces. Conventional crack-based resistive strain sensors can achieve high sensitivity and large strain ranges by exploiting the opening and closing of randomly distributed microcracks. However, the uncontrolled evolution of these cracks during prolonged use often leads to performance degradation and poor reliability. In this work, we present a novel resistive strain sensor featuring predefined hourglass-shaped cracks that precisely regulate resistance variations through controlled crack opening and closure under stretching and release. A serpentine array of hourglass-shaped cracks is laser-cut into a 3D-printed conductive TPU film, after which the crack gaps are closed by releasing a pre-stretched elastomer substrate. Through geometric design, crack contact and evolution are precisely controlled, enabling the cracks to open stably and symmetrically under tensile strain, thereby producing predictable and linear resistance changes. This design enables high sensitivity over a broad linear operating range. The sensor also exhibits excellent recoverability after overstretching well beyond its working window and shows negligible resistance variation under bending, highlighting its robustness for wearable applications. To demonstrate its practical utility, the sensor was integrated into athletes' strength-training tasks, and the acquired signals were analyzed using machine learning algorithms to recognize motion patterns and provide early warnings of over-exercise. These capabilities support real-time load adjustment and fatigue-risk management, underscoring the sensor's strong potential for wearable health monitoring and human-machine interface applications.