A dual-mode fiber-shaped flexible capacitive strain sensor fabricated by direct ink writing technology for wearable and implantable health monitoring applications

Flexible fiber-shaped strain sensors show tremendous potential in wearable health monitoring and human‒machine interactions due to their compatibility with everyday clothing. However, the conductive and sensitive materials generated by traditional manufacturing methods to fabricate fiber-shaped strain sensors, including sequential coating and solution extrusion, exhibit limited stretchability, resulting in a limited stretch range and potential interface delamination. To address this issue, we fabricate a fiber-shaped flexible capacitive strain sensor (FSFCSS) by direct ink writing technology. Through this technology, we print parallel helical Ag electrodes on the surface of TPU tube fibers and encapsulate them with a high dielectric material BTO@Ecoflex, endowing FSFCSS with excellent dual-mode sensing performance. The FSFCSS can sense dual-model strain, namely, axial tensile strain and radial expansion strain. For axial tensile strain sensing, FSFCSS exhibits a wide detection range of 178%, a significant sensitivity of 0.924, a low detection limit of 0.6%, a low hysteresis coefficient of 1.44%, and outstanding mechanical stability. For radial expansion strain sensing, FSFCSS demonstrates a sensitivity of 0.00086 mmHg-1 and exhibits excellent responsiveness to static and dynamic expansion strain. Furthermore, FSFCSS was combined with a portable data acquisition circuit board for the acquisition of physiological signals and human‒machine interaction in a wearable wireless sensing system. To measure blood pressure and heart rate, FSFCSS was combined with a printed RF coil in series to fabricate a wireless hemodynamic sensor. This work enables simultaneous application in wearable and implantable health monitoring, thereby advancing the development of smart textiles.