A 3D printed pressure sensor based on a bossed diaphragm with straight-annular grooves

Purpose To supply temporary pressure testing devices with favorable performance for emergency environments, this paper aims to present a pressure sensor with a central boss and straight-annular grooves. The structural feature is modeled and optimized by neural network-based method, and the device prototype is fabricated by 3D printing techniques. Design/methodology/approach The study initially compares mechanical properties of the proposed structure with two conventional designs using finite element analysis. The impacts from structural dimensions on sensor performance are modeled using a Backpropagation neural network and optimized through genetic algorithms. The sensing diaphragm is fabricated using stereolithography (SLA) 3D printing, while the piezoresistors and necessary interconnects are realized with screen printing techniques. Findings The experimental results demonstrate that the fabricated sensor exhibits a sensitivity of 2.8866 mV/kPa and a nonlinearity of 6.81% within the pressure range of 0–100 kPa. This performance is an improvement of 118% in sensitivity and a decrease of 54% in nonlinearity compared to flat diaphragm structure, highlighting the effectiveness of proposed diaphragm configuration. Originality/value This research offers a holistic methodology that encompasses the structural design, optimization and fabrication of pressure sensors. The proposed diaphragm and corresponding modelling method can provide a practical approach to enhance the measurement capabilities of pressure sensors. By leveraging SLA printing for diaphragm and screen printing for circuit, the prototype can be produced in a timely manner.