Microwave Radiation Assisted Construction of Fused Deposition Modeling 3D Printing Flexible Sensors

Abstract With the rapid development of the internet of things, the simple preparation of sensors has become a challenge. The present work presents the simple preparation of flexible sensors by using the fused deposition modeling (FDM) 3D printing combined with the microwave radiation‐assisted treatment of the thermoplastic polyurethane (TPU) with carbon nanotubes (CNTs) as conductive fillers to create the flexible sensors. The as‐prepared TPU/CNT composites exhibit the 7.27 MPa tensile strength and 401% elongation at break, similar to those of the pure TPU. After 200 tensile cycles, the TPU/CNT composites can still stably convert pressure into electrical signals, which can be used as flexible sensors with high sensitivity (0.879 kPa −1 ). In addition, shoe insoles and finger cover with sensing performance are fabricated through the FDM 3D printing technology, demonstrating the potential of the sensors to monitor human gait, finger straightening, and bending movements. The as‐proposed method involves the embedding CNTs as conductive fillers on the surface of TPU to form the TPU/CNT composite conductive layers on the surface of TPU, which is beneficial for maintaining the elasticity of the polymer matrix. The challenges in preparing stable, low‐cost, and scalable flexible sensors and highlights of the advantages of 3D printing technology in manufacturing flexible piezoresistive sensors are also deeply discussed.