A wearable, low-cost, highly repeatable piezoresistive sensor was fabricated by the synthesis of modified-graphite and polyurethane (PU) composites and polydimethylsiloxane (PDMS). Graphite sheets functionalized by using a silane coupling agent (KH550) were distributed in PU/N,N-dimethylformamide (DMF) solution, which were then molded to modified-graphite/PU (MG/PU) composite films. Experimental results show that with increasing modified-graphite content, the tensile strength of the MG/PU films first increased and then decreased, and the elongation at break of the composite films showed a decreasing trend. The electrical conductivity of the composite films can be influenced by filler modification and concentration, and the percolation threshold of MG/PU was 28.03 wt %. Under liner uniaxial compression, the 30 wt % MG/PU composite films exhibited 0.274 kPa−1 piezoresistive sensitivity within the range of low pressure, and possessed better stability and hysteresis. The flexible MG/PU composite piezoresistive sensors have great potential for body motion, wearable devices for human healthcare, and garment pressure testing.

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