Smart structures mimic biological systems by using thousands of sensors serving as a nervous system analog. One approach to give structures this sensing ability is to develop a multifunctional sensor network. Previous work has demonstrated stretchable sensor networks consisting of temperature sensors and impact detectors for monitoring external environments and interacting with other objects. The objective of this work is to develop distributed, robust and reliable strain gauges for obtaining the strain distribution of a designated region on the target structure. Here, we report a stretchable network that has 27 rosette strain gauges, 6 resistive temperature devices and 8 piezoelectric transducers symmetrically distributed over an area of 150 × 150 mm to map and quantify multiple physical stimuli with a spatial resolution of 2.5 × 2.5 mm. We performed computational modeling of the network stretching process to improve measurement accuracy and conducted experimental characterizations of the microfabricated strain gauges to verify their gauge factor and temperature coefficient. Collectively, the results represent a robust and reliable sensing system that is able to generate a distributed strain profile of a common structure. The reported strain gauge network may find a wide range of applications in morphing wings, smart buildings, autonomous cars and intelligent robots.

This article presents the development of a stretchable sensor network with high signal-to-noise ratio and measurement accuracy for real-time distributed sensing and remote monitoring. The described sensor network was designed as an island-and-serpentine type network comprising a grid of sensor “islands” connected by interconnecting “serpentines.” A novel high-yield manufacturing process was developed to fabricate networks on recyclable 4-inch wafers at a low cost. The resulting stretched sensor network has 17 distributed and functionalized sensing nodes with low tolerance and high resolution. The sensor network includes Piezoelectric (PZT), Strain Gauge (SG), and Resistive Temperature Detector (RTD) sensors. The design and development of a flexible frame with signal conditioning, data acquisition, and wireless data transmission electronics for the stretchable sensor network are also presented. The primary purpose of the frame subsystem is to convert sensor signals into meaningful data, which are displayed in real-time for an end-user to view and analyze. The challenges and demonstrated successes in developing this new system are demonstrated, including (a) developing separate signal conditioning circuitry and components for all three sensor types (b) enabling simultaneous sampling for PZT sensors for impact detection and (c) configuration of firmware/software for correct system operation. The network was expanded with an in-house developed automated stretch machine to expand it to cover the desired area. The released and stretched network was laminated into an aerospace composite wing with edge-mount electronics for signal conditioning, processing, power, and wireless communication.

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