This paper describes the use of free-standing electrically conductive ultra-low modulus materials that withstand elongations up to 1000% as sensors for the measurement of large strains. NanoSonic has developed novel, high performance, multifunctional polymers for use in self-assembly processing that result in durable free-standing conductive films -with both controlled nominal conductivity and Young's modulus. Such films exhibit a change in electrical conductivity as a function of tensile strain; whereby the magnitude of the change is controlled via chemical processing.

We report recent improvements of Metal Rubber TM strain sensors formed by electrostatic self-assembly (ESA) processing. The sensors may be used to measure strains from approximately 1 microstrain to several hundred percent strain, over gauge lengths ranging from approximately 1 millimeter to several tens of centimeters.

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We discuss recent improvements of Metal Rubber TM materials formed by electrostatic selfassembly (ESA) processing. Free-standing and mechanically robust sheets of Metal Rubber TM have been synthesized with electrical conductivities approximately one order of magnitude lower than those of bulk noble metals and with moduli from 1 to 100 MPa.