Fully Additively 3D Manufactured Conductive Deformable Sensors for Pressure Sensing

Additive manufacturing technologies increasingly revolutionize current production techniques for object manufacturing. Particularly, fused deposition modeling (FDM) strongly impacts production processes by enabling the cost-effective and efficient creation of structures with complex designs and innovative geometries. The use of conductive filaments in FDM printing is paving the way for the advancement of entirely printed sensors and circuits, although this domain is still in its early stages. In this article, the design and production of bilayer deformable pressure sensors fabricated using conductive thermoplastic polyurethane are investigated. The potential to vary the mechanical and electrical characteristics of FDM-printed components by adjusting printing parameters is explored. The influence of different levels of material infill (20%, 50%, and 100%) and different contact geometries between layers (domes, pyramids, and cylinders) is studied. Electromechanical tests are carried out to characterize the sensor, applying pressures up to 22 kPa. The 3D-printed pressure sensors demonstrate tunable mechanical and electrical sensitivities at different infill values, with the highest value of −6.3 kPa⁻¹ achieved by using a pyramid layer at 100% infill. Sensor outputs registered during cyclic tests show reproducible responses with a wide range of sensitivity, paving the way for applicability in recording both static and periodic pressure changes.