Printing the future of strain measurement: Flexible sensors via additive manufacturing for wearables, robotics, and smart infrastructure

Abstract

This review presents the evolution of strain sensor technologies from traditional bonded wire models to next-generation flexible designs enabled by advanced materials and additive manufacturing through 3D printing. It highlights breakthroughs in fabrication techniques particularly fused filament fabrication (FFF), direct ink writing (DIW), and vat photopolymerization (VPP) that address the limitations of conventional approaches, including complex multi-step processing and alignment challenges. The incorporation of novel materials such as conductive polymers and hybrid composites is shown to significantly enhance key performance parameters like sensitivity, mechanical durability, and strain sensing range. The convergence of cutting-edge manufacturing, material science, and computational modeling signals a paradigm shift in strain sensing, with broad implications for emerging applications in aerospace, biomedicine, soft robotics, and beyond. This work underscores the importance of continued interdisciplinary collaboration to fully realize the potential of flexible strain sensor technologies in adaptive, high-performance systems.