Development of Self‐Sensing Hybrid Fiber–Reinforced Polymer Composites: The Role of Piezoelectric Nanoparticles and Mesh Electrodes

ABSTRACT Self‐sensing multifunctional unsaturated polyester–glass fabric composites were developed using zinc oxide nanoparticles and copper mesh electrodes. The piezoelectric behavior of the zinc oxide filler enables the generation of an electrical signal under bending loads, allowing the material to serve as a load‐bearing structure and a sensing element simultaneously. The polymer composites produced an electrical response of 72.5 μV/MPa, while maintaining mechanical performance. A stable electromechanical coupling was observed, characterized by a linear correlation between the mechanical load and the resulting electrical signal. Hybridization with carbon‐fiber layers increased the deformation‐based sensitivity up to 2.56 mV/mm. The self‐sensing hybrid composites with embedded copper mesh electrodes exhibited flexural strengths of 230–270 MPa and flexural modulus of 24–27 GPa, depending on the ZnO content. These self‐sensing composites were fabricated from conventional materials and with cost‐effective processing techniques, highlighting their potential for industrial applications as both structural components and integrated sensors.