Wearable Tactile Sensors Customized with Hierarchical Microdomes via Direct Ink Writing

Abstract

3D printing presents a promising avenue for developing personalized healthcare devices. Among 3D printing techniques, direct ink writing (DIW) stands out for its versatility in fabricating wearable sensors for real‐time health monitoring. DIW not only enables the utilization of diverse materials but also offers the flexibility to produce various sensors quickly. In this study, a novel wearable tactile sensor with a customizable active layer realized through the DIW employing two distinct conductive inks with differing rheological and electrical properties is introduced. The resulting 3D‐printed active layers are flexible and micro‐structured, which facilitate real‐time physiological signal recording in health monitoring applications. By incorporating hierarchical microdomes atop a flat substrate, the dynamic response of the active layer is significantly enhanced. Additionally, the trapped pores within the 3D‐printed structures contribute to improved sensor performance in static tests. The 3D‐printed active layers exhibit excellent linearity and resolution in the range from 1 to 30 N, demonstrating their suitability for diverse applications tailored to specific requirements. This study offers a cost‐effective approach for fabricating tactile sensors customized for various wearable medical applications.