This contribution will introduce carbon-reinforced concrete components (so-called carbon concrete composites, or C3) with sensor functionalities for innovative building envelopes. For a continuous in situ structural monitoring, these textile-reinforced concrete components are equipped with textile sensor networks consisting of resistive carbon fiber sensors (CFSs), which are integrated into the carbon fiber non-crimp fabrics of the concrete reinforcement by multiaxial warp-knitting. The in situ CFSs, consisting of 1 k or 50 k carbon fiber roving with added staple fiber/multifilament dielectric cladding, are later integral to the load-distributing elements of the concrete component, and elongations within these are easy to record with good correlation to ohmic resistance changes. Gage factors of k = 0.52–1.23 at linearity deviations of ALin = 4.0–8.7% are feasible. This allows a monitoring of C3 building envelopes for structural mechanical changes caused by physical changes within the component through mechanical or thermal loads or deformation and cracks.

In the current paper the reliability of spring interconnections for the use in automotive applications was investigated. A commercially available connector was used for contacting a piezo-jet printed silver pad on polycarbonate. The structures were tested using vibration tests at three different temperatures (−25°C, 25°C and 85°C) and measured using four-point probe measurement system and white light spectrometry. The obtained results showed the reliability of the printed structure and the contact, despite of the contact resistance change. The reasons of this change and experimental results are discussed in the paper. The investigations described in the paper provide an initial approach to the development of spring interconnections for printed electronics.