Fabric-Based Dual-Mode Pressure Sensor System with a Wide Detection Range Fabricated via Direct Laser Writing

Compared to sensors based on a single sensing principle, dual-mode sensors that combine two sensing mechanisms offer significant advantages in terms of detection range and thresholds. However, the current fabrication process for dual-mode pressure sensors is complex, increasing equipment requirements and costs while limiting their widespread applications. This work formulates a simple strategy for fabricating a fabric-based resistive–capacitive dual-mode pressure sensor system using direct laser writing (DLW). Compared to single-mode resistive and capacitive pressure sensors fabricated using the same DLW method, the dual-mode pressure sensor exhibited a 94.17% reduction in the minimum detection threshold and a 150% increase in the pressure-detection range. In addition to conventional physiological monitoring, the dual-mode sensing system can be integrated into safety helmets to monitor drivers’ microexpressions and external forces. By leveraging the inherent advantages of fabric, this system enables the simultaneous integration of cargo packaging and force-monitoring functions. The proposed method effectively simplifies the fabrication process, reduces material consumption, and broadens the application of pressure sensors in road safety and logistics transportation. The simple fabrication of a dual-mode pressure sensor system via DLW offers a pathway to the low-cost, efficient development of high-performance flexible sensors.