Understanding the Design and Sensory Behaviour of Graphene-Impregnated Textile-Based Piezoresistive Pressure Sensors

Graphene-based textile pressure sensors are emerging as promising candidates for wearable sensing applications due to their high sensitivity, mechanical flexibility, and low energy consumption. This study investigates the design, fabrication, and electromechanical behaviour of graphene-coated nonwoven textile-based piezoresistive pressure sensors, focusing on the impact of different electrode materials and fabrication techniques. Three distinct sensor fabrication methods-drop casting, electrospinning, and electro-spraying-were employed to impregnate graphene onto nonwoven textile substrates, with silver-coated textile electrodes integrated to enhance conductivity. The fabricated sensors were characterised for their morphology (SEM), chemical composition (FTIR), and electromechanical response under cyclic compressive loading. The results indicate that the drop-cast sensors exhibited the lowest initial resistance (~0.15 kΩ) and highest sensitivity (10.5 kPa^-1) due to their higher graphene content and superior electrical connectivity. Electro-spun and electro-sprayed sensors demonstrated increased porosity and greater resistance fluctuations, highlighting the role of fabrication methods in sensor performance. Additionally, the silver-coated knitted electrodes provided the most stable electrical response, while spun-bonded and powder-bonded nonwoven electrodes exhibited higher hysteresis and resistance drift. These findings offer valuable insights into the optimisation of graphene-based textile pressure sensors for wearable health monitoring and smart textile applications, paving the way for scalable, low-power sensing solutions.