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Hydrogels, as classic soft materials, are important materials for tissue engineering and biosensing with unique properties, such as good biocompatibility, high stretchability, strong adhesion, excellent self-healing, and self-recovery. Conductive hydrogels possess the additional property of conductivity, which endows them with advanced applications in actuating devices, biomedicine, and sensing. In this review, we provide an overview of the recent development of conductive hydrogels in the field of strain sensors, with particular focus on the types of conductive fillers, including ionic conductors, conducting nanomaterials, and conductive polymers. The synthetic methods of such conductive hydrogel materials and their physical and chemical properties are highlighted. At last, challenges and future perspectives of conductive hydrogels applied in flexible strain sensors are discussed.

With the rapid development of smart products, flexible and stretchable smart wearable electronic devices gradually play an important role, and they are considered as the pioneers of the new generation of flexible electronic devices. Among these intelligent devices, flexible and stretchable strain sensors have been widely studied for their good flexibility, high sensitivity, high repeatability and huge potential for application in personal healthcare and motion detection. Moreover, unlike traditional rigid bulky sensors, the high-performance flexible strain sensors are lightweight portable devices with excellent mechanical and electrical performance, which can meet personalized needs and become more popular. Herein, the research progress of flexible strain sensors in recent years are reviewed, which mainly introducing the sensing principles and key parameters of strain sensors, commonly used conductive materials and flexible substrates and common preparation methods, and finally proposes the future application and prospects of strain sensors. Graphical abstract

Laser-induced graphene (LIG) has the advantages of one-step fabrication, prominent mechanical performance, as well as high conductivity; it acts as the ideal material to fabricate flexible strain sensors. In this study, a wearable flexible strain sensor consisting of three-dimensional (3D) wavy LIG and silicone rubber was reported. With a laser to scan on a polyimide film, 3D wavy LIG could be synthesized on the wavy surface of a mold. The wavy-LIG strain sensor was developed by transferring LIG to silicone rubber substrate and then packaging. For stress concentration, the ultimate strain primarily took place in the troughs of wavy LIG, resulting in higher sensitivity and less damage to LIG during stretching. As a result, the wavy-LIG strain sensor achieved high sensitivity (gauge factor was 37.8 in a range from 0% to 31.8%, better than the planar-LIG sensor), low hysteresis (1.39%) and wide working range (from 0% to 47.7%). The wavy-LIG strain sensor had a stable and rapid dynamic response; its reversibility and repeatability were demonstrated. After 5000 cycles, the signal peak varied by only 2.32%, demonstrating the long-term durability. Besides, its applications in detecting facial skin expansion, muscle movement, and joint movement, were discussed. It is considered a simple, efficient, and low-cost method to fabricate a flexible strain sensor with high sensitivity and structural robustness. Furthermore, the wavy-LIG strain senor can be developed into wearable sensing devices for virtual/augmented reality or electronic skin.

High-performance flexible pressure sensors have great application prospects in numerous fields, including the robot skin, intelligent prosthetic hands and wearable devices. In the present study, a novel type of flexible piezoresistive sensor is presented. The proposed sensor has remarkable superiorities, including high sensitivity, high repeatability, a simple manufacturing procedure and low initial cost. In this sensor, multi-walled carbon nanotubes were assembled onto a polydimethylsiloxane film with a pyramidal microarray structure through a layer-by-layer self-assembly system. It was found that when the applied external pressure deformed the pyramid microarray structure on the surface of the polydimethylsiloxane film, the resistance of the sensor varied linearly as the pressure changed. Tests that were performed on sensor samples with different self-assembled layers showed that the pressure sensitivity of the sensor could reach − 2.65     kPa − 1 , which ensured the high dynamic response ability and the high stability of the sensor. Moreover, it was proven that the sensor could be applied as a strain sensor under the tensile force to reflect the stretching extent or the bending object. Finally, a flexible pressure sensor was installed on five fingers and the back of the middle finger of a glove. The obtained results from grabbing different weights and different shapes of objects showed that the flexible pressure sensor not only reflected the change in the finger tactility during the grasping process, but also reflected the bending degree of fingers, which had a significant practical prospect.

High-performance flexible strain sensors are playing an increasingly important role in wearable electronics, such as human motion detection and health monitoring, with broad application prospects. This study developed a flexible resistance strain sensor with a porous structure composed of carbon black and multi-walled carbon nanotubes. A simple and low-cost spraying method for the surface of a porous polydimethylsiloxane substrate was used to form a layer of synergized conductive networks built by carbon black and multi-walled carbon nanotubes. By combining the advantages of the synergetic effects of mixed carbon black and carbon nanotubes and their porous polydimethylsiloxane structure, the performance of the sensor was improved. The results show that the sensor has a high sensitivity (GF) (up to 61.82), a wide strain range (0%–130%), a good linearity, and a high stability. Based on the excellent performance of the sensor, the flexible strain designed sensor was installed successfully on different joints of the human body, allowing for the monitoring of human movement and human respiratory changes. These results indicate that the sensor has promising potential for applications in human motion monitoring and physiological activity monitoring.

Because of their superior performance, flexible strain sensors are used in a wide range of applications, including medicine and health, human–computer interaction, and precision manufacturing. Flexible strain sensors outperform conventional silicon-based sensors in high-strain environments. However, most current studies report complex flexible sensor preparation processes, and research focuses on enhancing and improving one parameter or property of the sensors, ignoring the feasibility of flexible strain sensors for applications in various fields. Since the mechanical properties of flexible sensors can be well combined with rubber conveyor belts, in this work polydimethylsiloxane (PDMS) was used as a flexible substrate by a simple way of multiple drop coating. Graphene-based flexible strain sensor films that can be used for strain detection at the joints of steel cord core conveyor belts were successfully fabricated. The results of the tests show that the sensor has a high sensitivity and can achieve a fast response (response time: 43 ms). Furthermore, the sensor can still capture the conveyor belt strain after withstanding high pressure (1.2–1.4 MPa) and high temperature (150 °C) during the belt vulcanization process. This validates the feasibility of using flexible strain sensors in steel wire core conveyor belts and has some potential for detecting abnormal strains in steel wire core conveyor belt, broadening the application field of flexible sensors.

Highlights A method is proposed for the modulation of electrical pathways in the cracks of stretchable electrodes using liquid metals, based on which ultra-high sensitivity (> 10 8 ) and large-range (> 100%) strain sensors are realised. A secondary modulation of the response (or performance) of the sensor is proposed, allowing not only electrical modulation by liquid metal patterning during fabrication, but also mechanical modulation by pre-stretching at the time of use. The air permeability and stability of the patterned liquid metal electrode region is optimised to enable air permeability similar to that of conventional fabrics and cycle durability in excess of 2000 cycles. This study presents a breakthrough in flexible strain sensor technology with the development of an ultra-high sensitivity and wide-range sensor, addressing the critical challenge of reconciling sensitivity with measurement range. Inspired by the structure of bamboo slips, we introduce a novel approach that utilises liquid metal to modulate the electrical pathways within a cracked platinum fabric electrode. The resulting sensor demonstrates a gauge factor greater than 10 8 and a strain measurement capability exceeding 100%. The integration of patterned liquid metal enables customisable tuning of the sensor’s response, while the porous fabric structure ensures superior comfort and air permeability for the wearer. Our design not only optimises the sensor’s performance but also enhances the electrical stability that is essential for practical applications. Through systematic investigation, we reveal the intrinsic mechanisms governing the sensor’s response, offering valuable insights for the design of wearable strain sensors. The sensor’s exceptional performance across a spectrum of applications, from micro-strain to large-strain detection, highlights its potential for a wide range of real-world uses, demonstrating a significant advancement in the field of flexible electronics.

Flexible strain sensors have a wide range of applications in biomedical science, aerospace industry, portable devices, precise manufacturing, etc. However, the manufacturing processes of most flexible strain sensors previously reported have usually required high manufacturing costs and harsh experimental conditions. Besides, research interests are often focused on improving a single attribute parameter while ignoring others. This work aims to propose a simple method of manufacturing flexible graphene-based strain sensors with high sensitivity and fast response. Firstly, oxygen plasma treats the substrate to improve the interfacial interaction between graphene and the substrate, thereby improving device performance. The graphene solution is then sprayed using a soft PET mask to define a pattern for making the sensitive layer. This flexible strain sensor exhibits high sensitivity (gauge factor ~100 at 1% strain), fast response (response time: 400–700 μs), good stability (1000 cycles), and low overshoot (<5%) as well. Those processes used are compatible with a variety of complexly curved substrates and is expected to broaden the application of flexible strain sensors.

In order to replace nonrenewable resources and decrease electronic waste disposal, there is a rapidly rising demand for the utilization of reproducible and degradable biopolymers in flexible electronics. Natural biopolymers have many remarkable characteristics, including light weight, excellent mechanical properties, biocompatibility, non-toxicity, low cost, etc. Thanks to these superior merits, natural functional biopolymers can be designed and optimized for the development of high-performance flexible electronic devices. Herein, we provide an insightful overview of the unique structures, properties and applications of biopolymers for electronic skins (e-skins) and flexible strain sensors. The relationships between properties and sensing performances of biopolymers-based sensors are also investigated. The functional design strategies and fabrication technologies for biopolymers-based flexible sensors are proposed. Furthermore, the research progresses of biopolymers-based sensors with various functions are described in detail. Finally, we provide some useful viewpoints and future prospects of developing biopolymers-based flexible sensors.

The CNT-PDMS composite has been widely adopted in flexible devices due to its high elasticity, piezoresistivity, and biocompatibility. In a wide range of applications, CNT-PDMS composite sensors were used for resistive strain measurement. Accordingly, the percolation threshold 2%~4% of the CNT weight ratio in the CNT-PDMS composite was commonly selected, which is expected to achieve the optimized piezoresistive sensitivity. However, the linear range around the percolation threshold weight ratio (2%~4%) limits its application in a stable output of large strain (>20%). Therefore, comprehensive understanding of the electromechanical, mechanical, and electrical properties for the CNT-PDMS composite with different CNT weight ratios was expected. In this paper, a systematic study was conducted on the piezoresistivity, Young’s modulus, conductivity, impedance, and the cross-section morphology of different CNT weight ratios (1 to 10 wt%) of the CNT-PDMS composite material. It was experimentally observed that the piezo-resistive sensitivity of CNT-PDMS negatively correlated with the increase in the CNT weight ratio. However, the electrical conductivity, Young’s modulus, tensile strength, and the linear range of piezoresistive response of the CNT-PDMS composite positively correlated with the increase in CNT weight ratio. Furthermore, the mechanism of these phenomena was analyzed through the cross-section morphology of the CNT-PDMS composite material by using SEM imaging. From this analysis, a guideline was proposed for large strain (40%) measurement applications (e.g., motion monitoring of the human body of the finger, arm, foot, etc.), the CNT weight ratio 8 wt% was suggested to achieve the best piezoresistive sensitivity in the linear range.