Facile Laser Fabrication of Flexible Free Standing Thermal Sensor for Wall Shear Stress Detection

The transportation sector is a major source of global greenhouse gas emissions, contributing about a quarter of all energy-related carbon emissions. Enhancing transportation efficiency is crucial for reducing these emissions, with wall shear stress playing a key role in vehicle aerodynamics. This study presents a simple method for fabricating a flexible thermal sensor for wall shear stress detection. A thin nichrome foil was patterned using a ultraviolet (UV) laser and transferred onto various surfaces. This approach enabled the creation of a free-standing flexible microstructure. Infrared thermography confirmed localized heat dissipation, reducing thermal mass effects. Airflow tests demonstrated a response time under 20 ms, highlighting the sensor's potential for aerodynamic applications and eventually efficiency improvements in transportation systems.