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Recently, the stretchable piezoresistive composites have become a focus in the fields of the biomechanical sensing and human posture recognition because they can be directly and conformally attached to bodies and clothes. Here, we present a stretchable piezoresistive thread sensor (SPTS) based on Ag plated glass microspheres (Ag@GMs)/solid rubber (SR) composite, which was prepared using new shear dispersion and extrusion vulcanization technology. The SPTS has the high gauge factors (7.8~11.1) over a large stretching range (0–50%) and approximate linear curves about the relative change of resistance versus the applied strain. Meanwhile, the SPTS demonstrates that the hysteresis is as low as 2.6% and has great stability during 1000 stretching/releasing cycles at 50% strain. Considering the excellent mechanical strain-driven characteristic, the SPTS was carried out to monitor posture recognitions and facial movements. Moreover, the novel SPTS can be successfully integrated with software and hardware information modules to realize an intelligent gesture recognition system, which can promptly and accurately reflect the produced electrical signals about digital gestures, and successfully be translated into text and voice. This work demonstrates great progress in stretchable piezoresistive sensors and provides a new strategy for achieving a real-time and effective-communication intelligent gesture recognition system.

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