In the last decade, significant developments of flexible and stretchable force sensors have been witnessed in order to satisfy the demand of several applications in robotic, prosthetics, wearables and structural health monitoring bringing decisive advantages due to their manifold customizability, easy integration and outstanding performance in terms of sensor properties and low-cost realization. In this paper, we review current advances in this field with a special focus on polymer/carbon nanotubes (CNTs) based sensors. Based on the electrical properties of polymer/CNTs nanocomposite, we explain underlying principles for pressure and strain sensors. We highlight the influence of the manufacturing processes on the achieved sensing properties and the manifold possibilities to realize sensors using different shapes, dimensions and measurement procedures. After an intensive review of the realized sensor performances in terms of sensitivity, stretchability, stability and durability, we describe perspectives and provide novel trends for future developments in this intriguing field.

Abstract. A highly flexible, piezoresistive sensor matrix based on a carbon nanotube (CNT) polymer composite is developed for pressure distribution measurement applications. With an overall height of about 400 µm, the sensors can measure pressure directly, without any deformation elements, such as a cantilever or a deformation membrane. The measurement range is from 2.5 to 640 kPa. Both the position and the pressure of the applied load can be measured and visualized as a resistance change. The relative resistance measurement deviation of the data acquisition system is lower than 3 % for the resistance range of 610Ω to 380 kΩ. This corresponds to a systematic deviation of pressure measurement of less than 3 % in the measurement range. Besides the measurement of pressure, different sizes of loads can be detected as well. The developed fast and compact measurement system allows dynamic pressure measurement, such as gait analysis when used in an insole application.

Dispersion of carbon nanotubes (CNT) in solvents and/or polymers is essential to reach the full potential of the CNTs in nanocomposite materials. Dispersion of CNTs is especially challenging due to the van-der-Waals attraction forces between the CNTs, which let them tend to re-bundle and/or re-aggregate. This paper presents a brief analysis of the quality and stability of functionalized multiwalled carbon nanotubes (fMWCNT) dispersion on polar solvents. A comparative study of functionalized CNT dispersion in water, methyl, and alcohol-based organic solvents has been carried out and the dispersion has been characterized by UV-VIS spectroscopy, electrochemical characterization such as cyclic voltammetry (CV) and electrochemical impedance spectroscopy (EIS). Visual analysis of the dispersion has been investigated for up to 14 days to assess the dispersion’s stability. Based on the material characterization, it was observed that the degree of affinity fMWCNT with -COOH group highly depends on the polarity of the solvent, where the higher the polarity, the better the interaction of fMWCNT with solvents.

Foot pressure measurement plays an essential role in healthcare applications, clinical rehabilitation, sports training and pedestrian navigation. Among various foot pressure measurement techniques, in-shoe sensors are flexible and can measure the pressure distribution accurately. In this paper, we describe the design and characterization of flexible and low-cost multi-walled carbon nanotubes (MWCNT)/Polydimethylsiloxane (PDMS) based pressure sensors for foot pressure monitoring. The sensors have excellent electrical and mechanical properties an show a stable response at constant pressure loadings for over 5000 cycles. They have a high sensitivity of 4.4 kΩ/kPa and the hysteresis effect corresponds to an energy loss of less than 1.7%. The measurement deviation is of maximally 0.13% relative to the maximal relative resistance. The sensors have a measurement range of up to 330 kPa. The experimental investigations show that the sensors have repeatable responses at different pressure loading rates (5 N/s to 50 N/s). In this paper, we focus on the demonstration of the functionality of an in-sole based on MWCNT/PDMS nanocomposite pressure sensors, weighing approx. 9.46 g, by investigating the foot pressure distribution while walking and standing. The foot pressure distribution was investigated by measuring the resistance changes of the pressure sensors for a person while walking and standing. The results show that pressure distribution is higher in the forefoot and the heel while standing in a normal position. The foot pressure distribution is transferred from the heel to the entire foot and further transferred to the forefoot during the first instance of the gait cycle.

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