Digital Machine Knitted Resistive Strain Sensor for Wireless Human Motion Monitoring

Textile‐based wearable sensors are gaining popularity in healthcare and soft robotics due to their rapid, scalable, and low‐cost production. Among them, strain sensors have been drawing attention in various human motion detection and health monitoring applications. In this article, knitted strain sensors based on interlock structures have been fabricated for capturing human movement and their remote monitoring. To achieve high stretchability and electrical stability, elastic core spun (nylon/PU) with conductive (polyester/stainless steel) yarn has been realized to prototype the sensors. Six different samples with different yarn variations have been extensively investigated by various electromechanical characterizations. The developed strain sensors show a maximum gauge factor of 3.04 with excellent linearity ( R ² = 0.9911) and remarkable durability of 1500 cycles. These sensors also demonstrate rapid response (≈80 ms) and recovery time (≈120 ms) and exhibit good performance after 10 wash cycles, assessing the real‐world application of the sensors. To validate the applicability of the strain sensors in human motion monitoring, an elbow support guard and a kneecap have been constructed to demonstrate bending angle detection as well as wireless monitoring of various human locomotion. The developed strain sensors hold immense possibilities in health monitoring, physical rehabilitation, and sports applications.