Mechanically robust, flexible hybrid tactile sensor with microstructured sensitive composites for human-cyber-physical systems

Advances in human-cyber-physical system (HCPS) requires multiple and multimodal sensory network to address the challenge of human-machine relationships, posing substantial potential for human health monitoring and human-centric smart manufacturing. However, combining electrical sensitivity and mechanical robustness of flexible sensors with simple device structure is still challenging. This work presents a flexible porous bimodal pressure sensor (PBPS) by fabricating 3D microstructured sensitive porous carbon-nanotubes composites (PCNC). The multi-layered PBPS can offer the ability to switch between piezoresistive and piezocapacitive sensing modes without altering the device structure, enhancing mechanical stability of device under loading/unloading cycles. This versatility allows for the detection of hardness discrimination, grabbing sensing, and dynamic human physiological signal recognition, which possess superior pressure sensing performances with a high sensitivity (0.1059 kPa−1 in piezoresistive mode, 0.2054 kPa−1 in capacitive mode), wide measuring range (0–25 kPa), rapid response time (<130 ms in piezoresistive mode, <55 ms in piezocapacitive mode), and long-term durability (>3000 cycles). Furthermore, we proposed a mechanical constitutive model to elucidate the sensing mechanism of microstructured PCNC by 3D micro-CT based modeling and experimental data. Finally, we employed multiple PBPSs as sensing elements to real-time monitor 3D printing manufacturing stress, structure assembling stress, and human physiology signals in HCPS, indicating the potential applications of PBPS ranging from monitoring human health to facilitating intelligent manufacturing.