Efficient fabrication of flexible thermoplastic elastomer/carbon nanotubes piezoresistive sensor with surface microstructures and interface micropores for human motion monitoring

Flexible piezoresistive sensors are pivotal for next-generation wearable electronics, yet are fundamentally constrained by the sensitivity-range-stability trade-off inherent in conventional monoscale architectures. Herein, an efficient method that combines extrusion compression molding and sacrificial templating is proposed for the large-scale fabrication of the dual-microstructured thermoplastic elastomer (TPE)/carbon nanotubes (CNTs) sensor (MTCS). Through synergistic coordination between surface micropillar arrays and interface micropores, the MTCS achieves a 200 kPa detection range and sensitivity of up to 2.324 kPa −1 . At the same time, the sensor exhibits minimal signal degradation following 2000 compression cycles and demonstrates a response time of 146 ms. The micropillar/micropore coordination enables dynamic reconstruction of conductive networks during compression. Micropore collapse enhances through-threshold conduction while micropillar deformation enlarges surface contact area. The MTCS achieves a balanced optimization of sensitivity, detection range, and stability while possessing the advantage of large-scale manufacturing, with performance sufficient to meet demands in scenarios like routine human motion monitoring. The proposed strategy offers a promising approach for advancing the development of flexible piezoresistive sensors. • μ-ECM and sacrificial templating enable mass-fabrication of a dual-microstructured TPE/CNT sensor (MTCS). • MTCS's synergistic dual microstructures enable a broad 200 kPa detection range and high sensitivity of 2.324 kPa −1 . • The MTCS exhibits demonstrates stable cycle durability of over 2000 cycles and a response time of 146 ms. • The MTCS demonstrated the capacity for monitoring movements of multiple parts of the human body.