Scalable Manufacturing of Large-Area Pressure Sensor Array for Sitting Posture Recognition in Real Time

Pressure sensors are considered the key technology for potential applications in real-time health monitoring, artificial electronic skins, and human–machine interfaces. Despite the significant progress in developing novel sensitive materials and constructing unique sensor structures, it remains challenging to fabricate large-area pressure sensor arrays due to the involvement of complex procedures including photolithography, laser writing, or coating. Herein, a scalable manufacturing approach for the realization of pressure sensor arrays with substantially enlarged sensitive areas is proposed using a versatile screen-printing technique. A compensation mechanism is introduced into the printing process to ensure the precise alignment of conductive electrodes, insulation layers, and sensitive microstructures with an alignment error of less than 4 μm. The fully screen-printed sensors exhibit excellent collective sensing performance, such as a reasonable pressure sensitivity of −2.2 kPa^–1, a fast response time of 40 ms, and superior durability over 3000 consecutive pressures. Additionally, an integrated 16 × 32 pressure sensor array with a sensing area of 190 × 380 mm² is demonstrated to precisely recognize the sitting postures and the body weights, showing great potential in continuous and real-time health status monitoring.