High-precision resistance strain sensors of multilayer composite structure via direct ink writing: Optimized layer flatness and interfacial strength

Abstract The layer flatness and interfacial strength for the direct ink writing (DIW)-fabricated multilayer sensors are two significant factors in dominating the printing precision and the structural integrity of the sensors, respectively. However, it is still a challenge to control the interfacial strength and layer flatness of the multilayer sensors due to the multiplicity of materials and inherent lines-to-plane forming process of DIW technology. Here we probe a set of DIW fabrication parameters to optimize the layer flatness and design the interfacial strength of the multilayer sensors. The nonlinear thickness-dependent interfacial strength is then measured by single-lap joints experiments, which can be further predicted by an analytical model and finite element simulations. Finally, the high precision and stability of the printed strain sensors with considerably flat layers and high interfacial strength are further tested under static and cyclic tensile loadings. This study provides a feasible approach for parametrically designing and precisely manufacturing multilayer sensors based on the widely used DIW technology.