Tailoring Piezoresistive Performance in 3D-Printed Nanocomposite Sensors Through Cellular Geometries

Flexible nanocomposite sensors hold significant promise in various applications, such as wearable electronics and medical devices. This research aims to tailor the flexibility and sensitivity of 3D-printed piezoresistive nanocomposite pressure sensors through geometric design, by exploring various simple cellular structures. The geometric designs were specifically selected to be 3D printable with a flexible material, allowing evaluation of the impact of different structures on sensor performance. In this study, we used both experimental and finite element (FE) methods to investigate the effect of geometric design on piezoresistive sensors. We fabricated the sensors using a flexible resin mixed with conductive nanoparticles via a Stereolithography (SLA) additive manufacturing technique. Electromechanical testing was carried out to evaluate the performance of four different sensor designs. Finite element (FE) models were developed, and their results were compared with experimental data to validate the simulations. The results demonstrated that auxetic structure exhibited the highest sensitivity and lowest stiffness both in experimental and FE analysis, highlighting its potential for applications requiring highly responsive materials. The validated FE model was further used for a parametric study of one of the promising simple designs, revealing that variations in geometric parameters significantly impact piezoresistive sensitivity. These findings provide valuable insights for advancing the development of pressure sensors with tailored sensitivity characteristics.