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<p>Flexible and highly sensitive strain sensors are essential for wearable electronics, human–machine interfaces, and health-monitoring applications. In this study, screen-printed zigzag piezoresistive strain sensors were fabricated using graphene nanoplatelet–polydimethylsiloxane (GNP–PDMS) composite inks, and the effects of solvent selection and sensor geometry on electromechanical performance were systematically investigated. Among the investigated solvents, the toluene-based ink produced the most stable dispersion and highest sensitivity, achieving a gauge factor (GF) of 99.7 at 70% strain. Optimization of zigzag geometry further enhanced performance. The optimized sensor, with a line width of 2.3 mm and a zigzag angle of 30 deg, exhibited a normalized resistance change (Δ<i>R</i>/<i>R</i><sub>0</sub>) of 424.06 and a GF of 605.8 at 70% strain. The sensor also exhibited low hysteresis, repeatable behavior over 100 loading–unloading cycles, and fast response/recovery characteristics. Human motion monitoring, including finger, elbow, and knee bending, as well as phonation-related throat motion detection, confirmed its suitability for real-time biomechanical monitoring. These findings highlight the combined importance of solvent engineering and geometry optimization in developing high-performance wearable strain sensors through a scalable screen-printing process.</p>

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A wearable zigzag strain sensor based on screen-printed GNPs-PDMS composites for real-time human motion monitoring

  • 期刊论文

  • 发表日期：

    2026年7月21日

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  • Syed Muzamil Ahmed,
  • Sharifah Fatmadiana Wan Muhamad Hatta,
  • Norhayati Soin,
  • Yasmin Abdul Wahab

摘要

Flexible and highly sensitive strain sensors are essential for wearable electronics, human–machine interfaces, and health-monitoring applications. In this study, screen-printed zigzag piezoresistive strain sensors were fabricated using graphene nanoplatelet–polydimethylsiloxane (GNP–PDMS) composite inks, and the effects of solvent selection and sensor geometry on electromechanical performance were systematically investigated. Among the investigated solvents, the toluene-based ink produced the most stable dispersion and highest sensitivity, achieving a gauge factor (GF) of 99.7 at 70% strain. Optimization of zigzag geometry further enhanced performance. The optimized sensor, with a line width of 2.3 mm and a zigzag angle of 30 deg, exhibited a normalized resistance change (ΔR/R0) of 424.06 and a GF of 605.8 at 70% strain. The sensor also exhibited low hysteresis, repeatable behavior over 100 loading–unloading cycles, and fast response/recovery characteristics. Human motion monitoring, including finger, elbow, and knee bending, as well as phonation-related throat motion detection, confirmed its suitability for real-time biomechanical monitoring. These findings highlight the combined importance of solvent engineering and geometry optimization in developing high-performance wearable strain sensors through a scalable screen-printing process.