Design of 3D-Printed strain-responsive TPU/WS2/CB nanocomposites as dual-function flexible supercapacitor electrodes

In this study, a multifunctional strain-responsive supercapacitor (SC) was developed by integrating tungsten disulfide (WS 2 ) and carbon black (CB) into a 3D-printed thermoplastic polyurethane (TPU) matrix. This device simultaneously serves as an energy storage unit and a strain sensor. The incorporation of 1.5 wt% WS 2 into TPU and treating with 0.5 wt% CB in ethanol within the TPU framework significantly enhanced the electrochemical and mechanical properties, achieving an areal capacitance of 206.5 mF cm -2 , outstanding cyclic stability of 98% over 10,000 charge-discharge cycles, and superior strain sensitivity. The electrochemical impedance spectroscopy, cyclic voltammetry, and galvanostatic charge-discharge analysis confirmed the high charge storage capability and low internal resistance of the composite electrodes. Additionally, strain-sensing experiments demonstrated a strong linear correlation between mechanical deformation and electrical resistance, with a gauge factor in the range of 1000–1500 and an R 2 value of 0.939, validating the exceptional strain sensitivity and reliability of the sensor. By combining mechanical flexibility, superior electrochemical performance, and real-time strain sensing capabilities, the 3D-printed TPU/WS 2 /CB composite offers a highly adaptable and efficient solution for health monitoring devices, smart textiles, and next-generation electronic interfaces. This 3D-printed work advances dual-function energy storage and sensing systems, eliminating the need for separate sensing components while enhancing space utilization and reducing system complexity. • 3D-printed TPU/WS 2 /CB nanocomposites serve as dual-function flexible electrodes. • Optimized composites achieved 206.5 mF cm -2 areal capacitance and 98% cyclic stability. • Electrodes exhibit high strain sensitivity with a gauge factor of 1000-1500 and R 2 value of 0.939. • WS 2 and CB synergistically enhance electrochemical and mechanical properties.