Aerosol Jet Printing of Strain Sensors for Soft Robotics

The field of soft robotics is rapidly progressing toward applications including; wearable electronics, prosthetics, and biomedical devices. This is leading to demand for flexible, embedded high‐performance strain sensors to deliver real‐time feedback on the static configurations and dynamic motions of these robotic devices, to ultimately enable the levels of autonomous control and structural monitoring required for intelligent manipulation. Herein, aerosol jet printing (AJP) technology is utilized to generate arbitrary piezoresistive strain sensor layouts on fibrous paper suitable for direct integration into elastomeric soft robots. A custom graphene nanoplatelet ink with a viscosity of around 2.70 cP has been formulated for optimized atomization and patterning of conductive traces via AJP. Single and multilayer printing onto different paper substrates are explored; with the nominal resistance of the printed tracks varying from 272 to 4900 kΩ depending on paper type and number of layers. Maximum gauge factors of 24.2 ± 1.8 and 56.5 ± 4.5 are determined for sensor surfaces under tensile and compression modes, respectively. To demonstrate the possibility for direct integration of this approach for soft robotics, strain sensors are directly printed onto the strain‐limiting layer of a pneumatic soft robotic gripper, to provide continuous feedback of the gripper over curvatures up to 80 m⁻¹.