High-strength fibrous sensors with an enhanced aggregate state for biomechanical monitoring of the Achilles tendon†

Continuous monitoring of biomechanical signals generated from the injured Achilles tendon is essential for the deep understanding of the recovery or rehabilitation process, thus decreasing the risk of secondary injuries. With tissue-like components and adjustable properties, hydrogel-based biomechanical sensors are considered promising materials for human motion detection. However, existing hydrogels are characterized by inferior mechanical properties with strength and modulus typically lower than 1 MPa, as well as poor stability under physiological conditions, which hampers their applications in implantable devices. Moreover, acquiring the stress signal from collected electrical signals remains challenging. Herein, based on the regulation of polymer aggregation, a high-strength fibrous sensor composed of polyvinyl alcohol (PVA) and reduced graphene oxide (rGO) for in vivo monitoring is prepared through a two-step procedure, including freeze–thaw and freeze–soak. Benefiting from the synergy of crystallization, Hofmeister effect and nanocomposite, the hydrogel fibers feature high tensile strength (8.34 ± 0.66 MPa) and elastic modulus (1.15 ± 0.10 MPa). Meanwhile, the removal of salt ions during fabrication improves the water content (69.18 ± 1.47%) and anti-swelling performance of such fibers and minimizes side effects after implantation. It is demonstrated that the fibrous sensor could record the relative resistance changes upon stretching with ideal sensitivity (GF = 1.57) and convert them into bearing stress through formula derivation and calculations. In vitro and in vivo assays further confirm its feasibility for real-time monitoring of joint motion, providing important references for medical diagnosis and treatment.