Mold-assisted self-assembled electrospun fiber membranes with ordered microstructure arrays for flexible pressure sensors

Electrospun fiber membranes demonstrate promising potential for developing wearable flexible pressure sensors with enhanced breathability and exceptional sensing capabilities. However, the fabrication of electrospun membranes featuring three-dimensional structures to further improve sensor performance remains a significant technical challenge. This study proposes an innovative beaded fiber-based mold-assisted self-assembly method to prepare electrospun fiber membranes with ordered microstructure arrays (EFM-OMAs). Then, the flexible pressure sensor based on EFM-OMAs was obtained, with a high sensitivity of 63.41 kPa −1 , a wide detection range of 0–110 kPa, an ultra-low detection limit of 0.92 Pa and excellent durability (10,000 cycles). Finally, the flexible pressure sensor was embedded in smart clothing, enabling real-time and accurate monitoring of physiological signals in the human body. Additionally, the sensor's breathable design facilitates efficient sweat expulsion, thereby reducing the risk of skin inflammation. This technology demonstrates potential for wearable applications, including intelligent healthcare systems, smart sports equipment, and human-computer interaction interfaces.