A flexible piezoresistive pressure sensor with high sensitivity and wide sensing range based on TPU/PCL/MXene@PEDOT:PSS nanofibers

To overcome the difficulty of forming stable and continuous conductive pathways of MXene in conventional electrospinning systems, we develop a high-performance flexible pressure sensor featuring a synergistic embedded–coated dual conductive architecture. A TPU/PCL nanofiber membrane uniformly incorporating MXene is fabricated via one-step electrospinning, followed by PEDOT:PSS dip-coating to construct an external conductive layer. Subsequent Ecoflex 00–30 encapsulation ensures mechanical integrity and maintains continuous multilevel electron-transport networks. Structural characterizations confirm the homogeneous incorporation of MXene within the nanofibers and the continuous surface coverage of PEDOT:PSS. The optimized sensor exhibits a maximum sensitivity of 7.05 kPa⁻¹ in the low-pressure region, together with a broad sensing range up to 100 kPa, enabling reliable detection across both subtle and high-pressure regimes. It further demonstrates fast dynamic response (0.11 s/0.31 s for response/recovery), a low detection limit of 50 Pa, and excellent durability over 2000 loading cycles. Demonstration tests confirm its ability to detect subtle physiological motions at different body locations, such as wrist movements and throat motions during swallowing, as well as various joint motions. Overall, this synergistic dual conductive strategy offers a promising platform for wearable health monitoring, electronic skins, and human–machine interaction.