Design approaches for high-temperature-resistant flexible pressure sensors in extreme environments

High-temperature-resistant flexible pressure sensors are critical for distributed monitoring in extreme environments such as aerospace, automotive engineering, firefighting, chemical reactors, and nuclear industries, where temperatures often exceed 200 °C and can reach up to 1000 °C. Traditional sensors face multiple limitations: inorganic-based sensors exhibit high brittleness and cannot conform to curved surfaces, while organic polymer-based sensors are prone to degradation and failure at elevated temperatures. This paper systematically reviews design strategies for high-temperature-resistant flexible pressure sensors based on four sensing mechanisms: piezoresistive, capacitive, piezoelectric, and triboelectric. It compares the advantages and disadvantages of different technical approaches. Furthermore, it elaborates on key concepts for optimizing sensor material systems (coordinating high-temperature stability, flexibility, and conductivity) and structural design (nanofiber networks, porous aerogels, and spring-like biomimetic structures). This paper comprehensively reviews cutting-edge technologies in this field, providing guidance for developing next-generation flexible pressure sensors for extreme thermal environments. It identifies future development directions, offering critical technical references for the intelligent upgrading of high-end equipment and sustainable industrial development.