Tailoring Strain Sensor Performance by Biwetting–Dewetting Assembly

The performance indices of nanomaterial-based strain sensors are typically mutually constrained; however, diverse applications necessitate customizable sensing performance for reliable detection. Programming the performance of strain sensors using simple methods and materials remains a significant challenge. Here, we report a biwetting–dewetting (BWD) assembly method for fabricating programmable strain sensors utilizing silver nanowire (AgNW)-based composites on polydimethylsiloxane (PDMS). The BWD assembly was conducted on a highly heterogeneous PDMS surface achieved by oxidation treatment. Patterned AgNWs can self-assemble on the PDMS via a wetting–dewetting process during spin coating. By leveraging the permeability of the AgNW network, a second ink of adhesive molecules, brittle polymers, MXene, or liquid metal particles can be selectively deposited on the AgNW patterns through the same wetting–dewetting process. The straightforward BWD method provides unparalleled tunability of sensitivity and stretchability, allowing for modulation of sensitivity (gauge factor: 2.3 to 3.1 × 106) by 2 to 6 orders of magnitude within 100% strain. With this customized performance, the AgNW-based sensors demonstrate reliable detection capabilities for sound vibration and various physiological motions. The BWD method introduces an innovative approach to tailoring strain sensor performance and holds potential applicability in assembling other nanomaterials for stretchable electronics.