Development of piezoresistive PDMS/MWCNT foam nanocomposite sensor with ultrahigh flexibility and compressibility

Polymer foam nanocomposites attract great interest in many wide ranges of biomedical and healthcare monitoring applications. In this study, we investigated the effect of porosity and multi-walled carbon nanotube (MWCNT) content on the piezoresistivity, sensitivity, and mechanical properties of Polydimethylsiloxane (PDMS)/MWCNT foam nanocomposite. The foam nanocomposites were fabricated by particulate leaching method and their electrical and mechanical characteristics were investigated using the different porosity levels (60% and 70%) and different conductive nanofiller contents (0.5 wt.% and 1 wt.%). The foam nanocomposites with 0.5 wt.% MWCNT content and 60% porosity possessed higher pressure sensitivity, higher gage factor, and lower electrical hysteresis along with higher mechanical properties. Moreover, fabricated PDMS/MWCNT foam nanocomposite demonstrated high flexibility, high compressibility, and high recoverability in addition to limited mechanical hysteresis (less than 3%) with a large dynamic sensing range. Contrary to the existing foam nanocomposite samples in the literature, PDMS/MWCNT foam nanocomposites withstood higher pressure ranges (3.5–5 MPa) at limited thickness (average 2.3 mm) without experiencing noticeable macroscopic damage.