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<p>Flexible, high-sensitivity, breathable strain sensors have great potential for application in wearable electronics. Existing wearable sensors are usually assembled with polymer encapsulation layers on thin-film substrates. The discomfort caused by low permeability and mechanical mismatch restricts people’s enthusiasm for selection. In this work, high-adhesion conductive graphite–carbon black composite inks were prepared using modified epoxy as the binding agent. Durable, breathable, and wearable strain sensors were successfully fabricated by dip-padding knitted fabrics with the conductive composite ink. The developed graphite composite sensor exhibits a broad tension sensing range (up to 20%) with high sensitivity (gauge factor up to 64), a wide pressure sensing range (0–50&#xa0;kPa), fast response/recovery times (60 ms/70 ms) under pressure strain, and good air permeability and mechanical durability. Additionally, this wearable sensor can effectively detect subtle-scale pulse signals and large-scale human movements, showcasing promising applications in practical wearable electronics for continuous and reliable human behavior monitoring.</p>

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Graphite Composite Ink-Modified Knitted Fabric for Fabricating Highly Sensitive, Robust, and Breathable Wearable Monitoring Sensors

  • 期刊论文

  • 发表日期：

    2026年3月16日

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  • Meng Dong,
  • Jun Cai,
  • Ruokai Wu,
  • Juan Hao,
  • Kaihong Wu,
  • Hui Dong

摘要

Flexible, high-sensitivity, breathable strain sensors have great potential for application in wearable electronics. Existing wearable sensors are usually assembled with polymer encapsulation layers on thin-film substrates. The discomfort caused by low permeability and mechanical mismatch restricts people’s enthusiasm for selection. In this work, high-adhesion conductive graphite–carbon black composite inks were prepared using modified epoxy as the binding agent. Durable, breathable, and wearable strain sensors were successfully fabricated by dip-padding knitted fabrics with the conductive composite ink. The developed graphite composite sensor exhibits a broad tension sensing range (up to 20%) with high sensitivity (gauge factor up to 64), a wide pressure sensing range (0–50 kPa), fast response/recovery times (60 ms/70 ms) under pressure strain, and good air permeability and mechanical durability. Additionally, this wearable sensor can effectively detect subtle-scale pulse signals and large-scale human movements, showcasing promising applications in practical wearable electronics for continuous and reliable human behavior monitoring.