Bioinspired Soft Strain Sensors Based on Screen-Printed TPU Nonwovens for Wearable Robotics

This study presents a bionic-inspired approach for fabricating soft strain sensors with intelligent response behavior, aimed at applications in wearable robotics and human–machine interaction. Thermoplastic polyurethane (TPU) meltblown nonwoven fabrics were used as the elastic substrate, on which conductive patterns were formed via screen printing. The influence of structural parameters, ink composition, and post-treatment conditions on sensor performance was systematically investigated. Results show that the developed sensors exhibit excellent stretchability, mechanical stability, and electrical responsiveness under cyclic deformation, enabling reliable signal transduction in dynamic environments. Their performance in joint motion monitoring and real-time resistance response highlights their potential in soft robotics, electronic skin, and biomimetic wearable systems.