A Microstructured‐Enhanced Flexible Sensor With Integrated Sensing and Adhesion for UAV Status Monitoring

ABSTRACT Flexible sensors are pivotal to advancements in intelligent robotics, health monitoring, and aerospace. Conventional sensors struggle to balance wide‐range detection and integrated adhesion, so this study proposes a microstructure‐enhanced polyvinyl chloride/multi‐walled carbon nanotubes (MWCNTs) polymer gel (MPG) sensor. It achieves integrated sensing and adhesion by fabricating a microcolumn array with a diameter of 20 µm and a height of 60 µm. The microstructures boost interfacial adhesion up to 301 mN/cm ² via increased contact area and convert mechanical deformation into electrical signals efficiently for pressure sensing using high aspect ratio. At 0.4 wt% MWCNTs content, the sensor shows optimal performance. It delivers an output voltage of 4.7 V under 100 kPa and a response time of 173 ms. Even at 0.2 wt% MWCNTs content, it maintains stable output after 600 compression cycles, with a mechanical recovery rate of ≥96% and excellent thermal stability. Its effectiveness and application potential in complex scenarios are verified by micro‐UAV negative‐surface adhesion landing tests and dynamic wing data acquisition of fixed‐wing UAVs throughout taxiing, takeoff, cruising, and landing. This research provides new solutions for flexible electronics, intelligent robotics, and aerospace structural health monitoring.