Polyurethane-Based Composites for Flexible Sensors: A Review

The rapid advancement of flexible electronics technology has endowed flexible sensors with significant application potential in fields such as wearable sensors, bionic skin, and human–machine interaction, owing to their excellent conformability, stretchability, and comfort. However, as application scenarios continue to expand and deepen, higher requirements are imposed on sensor performance in terms of sensitivity, stability, biocompatibility, environmental friendliness, and multifunctional integration. Polyurethane composites, leveraging their intrinsic characteristics, including tunable molecular structure, superior flexibility, and good biocompatibility, can effectively impart properties such as electrical conductivity, self-healing capability, and high sensitivity through compositing with various functional materials, thereby precisely aligning with the diverse demands of next-generation flexible sensors. This article systematically reviews the synthesis strategies of polyurethane composites; provides a detailed analysis of the roles of fillers—including carbon-based materials, polymers, and metal nanoparticles/nanowires—in enhancing the mechanical, electrical, and functional properties of the composites; and further summarizes the research progress of polyurethane composite-based flexible sensors in cutting-edge areas such as eco-friendly sensing, human motion monitoring, health monitoring, and bionic electronic skin. Future development trends are also discussed, aiming to provide insights for the design and development of high-performance flexible sensors.