用多材料打印与自动缝制一体成型可拉伸传感器，直接嵌入衣物。
Multi-material Direct Ink Writing and Embroidery for Stretchable Wearable Sensors
- 通过硅胶-碳油膏-硅胶多层打印+自动缝制，实现机械固定与电连接一体化。
- 传感器拉伸达120%仍导电，60%应变内线性度高（R²=0.99），灵敏度达31.4。
- 适合运动监测、康复和软体机器人，可批量集成于服装中。
可穿戴传感系统在运动表现追踪、康复与伤防领域的应用，推动了兼具舒适性、耐用性与精准运动检测能力的智能服装需求。本文提出一种纺织品兼容的制造流程，将多材料直接墨水书写与自动化缝制结合，实现可拉伸应变传感器在衣物中的直接嵌入。该工艺采用硅胶-碳油膏-硅胶多层顺序打印，并通过自动化缝制完成机械固定与电连接，一步完成。所得混合传感器在120%拉伸下保持电连续性，60%应变内呈近似线性（R²=0.99），灵敏度达31.4，滞后为22.9%。80次循环加载测试显示，每周期基线漂移0.135%，峰值漂移0.236%，表明具有中等循环稳定性。力学测试证实硅胶-织物界面在大变形下仍完整，失效发生于织物本身而非缝合边界。作为初步概念验证，传感器被集成于腕部与膝部护套中，用于关节角度监测，结果显示归一化电阻变化与弯曲角度存在清晰相关性。该方法通过缝制集成同时解决机械固定与电连接问题，为印刷可拉伸电子器件在纺织系统中的可重复、可扩展集成提供了路径，适用于运动捕捉与软体机器人应用。
原文摘要 · Abstract (English)
The development of wearable sensing systems for sports performance tracking, rehabilitation, and injury prevention has driven growing demand for smart garments that combine comfort, durability, and accurate motion detection. This paper presents a textile-compatible fabrication workflow that integrates multi-material direct ink writing with automated embroidery to create stretchable strain sensors directly embedded into garments. The process combines sequential multi-material printing of a silicone-carbon grease-silicone stack with automated embroidery that provides both mechanical fixation and electrical interfacing in a single step. The resulting hybrid sensor demonstrates stretchability up to 120% strain while maintaining electrical continuity, with approximately linear behaviour up to 60% strain (R^2 = 0.99), a gauge factor of 31.4, and hysteresis of 22.9%. Repeated loading-unloading tests over 80 cycles show baseline and peak drift of 0.135% and 0.236% per cycle, respectively, indicating moderate cycle-to-cycle stability. Mechanical testing further confirms that the silicone-fabric interface remains intact under large deformation, with failure occurring in the textile rather than at the stitched boundary. As a preliminary proof of concept, the sensor was integrated into wearable elbow and knee sleeves for joint angle monitoring, showing a clear correlation between normalised resistance change and bending angle. By addressing both mechanical fixation and electrical interfacing through embroidery-based integration, this approach provides a reproducible and scalable pathway for incorporating printed stretchable electronics into textile systems for motion capture and soft robotic applications.
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