Piezoresistive Performance of a Compliant Scalable Sensor Made of Low‐Cost Exfoliated Graphite Polymer Composites

Compliant sensors have drawn considerable interests in human–robot interactions. However, it is still challenging to obtain reliable and reproducible performance at reduced costs, especially for scaled‐up sensing applications. This work investigates the piezoresistive performance of a low‐cost, scalable sensor, which is made by spray coating exfoliated graphite natural rubber latex composites (EG/latex) over an elastomeric substrate. The EG/latex sensor provides a uniform distribution in the sheet resistance (variation below 4%) over a large 10 cm × 10 cm area. The stabilized piezoresistive response under cyclic tests is found highly related to both the filler concentration and the strain region. The 8 wt% and the 10 wt% sensors show nonlinear piezoresistive response, while the 25 wt% sensor exhibits the best linearity with a high gauge factor (7.6) and the lowest hysteresis (0.043) under a maximum strain of 60%. The distinct piezoresistive behavior is found attributed to the different levels of microbreakage under the applied strain. Scalable sensing performance is demonstrated on a hand‐size glove spray‐coated with 25 wt% EG/latex. Effective localization of contacts over the continuous sensing glove is achieved via the technique of electrical impedance tomography, validating the potential of the cost‐competitive EG/latex sensor for scalable sensing applications.