Interface-Enhanced Fiber Networks via Hybrid Near- and Far-Field Electrospinning for Highly Sensitive Stretchable Sensors

Textile-based strain sensors are essential components in wearable electronics due to their unique properties, including flexibility, stretchability, and air permeability. However, achieving high sensitivity while maintaining practicality remains a significant challenge. This study reports a strain sensor engineered via hybrid near- and far-field electrospinning (HNFE) of thermoplastic polyurethane (TPU), incorporating a hierarchical fiber network with oriented and disordered fibers and a conductive carbon nanotube interface. The design achieves an impressive gauge factor (GF) of 9008 at 307% strain, offering exceptional sensitivity across a broad strain range. Experimental results reveal outstanding repeatability, with negligible variation after 6000 cycles under 30% strain and a minimal detection threshold of 0.1%. The sensor exhibits a rapid response and recovery time of 190 ms, coupled with excellent durability and breathability, making it particularly suited for wearable applications. This versatile platform enables real-time monitoring of human motion, supporting advancements in wearable health tracking, precision sports analysis, and interactive systems, thus, addressing critical needs in next-generation flexible electronics.