Superstretchable
resistive strain sensors can reversibly undergo
severe deformations in response to different mechanical stimuli, leading
to a variation in their ohmic resistance. They are finding an increasing
number of applications in wearable electronics, biomedical devices,
and soft robotics. The development of fabrication process of reliable,
highly sensitive, and biocompatible superstretchable strain sensors
remains a challenge, especially in view of their integration with
medical devices. Here, we demonstrate the fabrication of a high-strain
resistive sensor based on Ecoflex elastomeric films and conductive
Au clusters, obtained by supersonic cluster beam deposition. An extensive
characterization of the electromechanical behavior of the sensor shows
stable operation up to 4500 working cycles, with a maximum strain
of 500% and a gauge factor of 124. Different mechanical stimuli, such
as elongation and indentation, can be detected, and the easy coupling
of the sensor with an inflatable balloon-type urinary catheter is
demonstrated. Aiming at shedding light on the observed electromechanical
mechanisms, the nanostructured morphology of the metal–polymer
hybrid layer was investigated by low-vacuum scanning electron microscopy.