Cleanroom-free fabrication of flexible capacitive pressure sensors using paintable silver electrodes on stationery paper and random microstructured polydimethylsiloxane dielectric layer

Abstract In this work, we propose a facile, low-cost, and cleanroom-free approach for fabricating flexible capacitive pressure sensors based on paintable Ag electrodes on stationery paper substrates (Ag–paper electrodes) and a random microstructured polydimethylsiloxane (PDMS) dielectric layer transferred from emery paper. COMSOL Multiphysics simulations and experimental investigations suggest that the pressure sensor with random microstructured PDMS dielectric layer performs better than the sensor with ordered micropyramidal dielectric layer. The developed Ag–paper electrode and random microstructured PDMS dielectric layer-based pressure sensors are workable in a wide pressure range (up to 630 kPa) and exhibit a high sensitivity of 0.132 kPa −1 up to 1 kPa, low hysteresis (6.6%) with loading–unloading of ∼500 kPa pressure, high stability during a ∼5250 cyclic test, and the ability to sense a low pressure of ∼27 Pa. The developed sensor also successfully transduces arterial pulse wave forms when it is properly attached to the wrist. Using the proposed process, a flexible capacitive pressure sensor matrix of 4 × 4 array is also successfully developed for single- and multiple-point pressure mapping with minimal cross-talk. The proposed sensor process is simple and inexpensive to implement, and offers spatial pressure mapping for e-skin applications.