Stretchable Polymer Foam Sensor Detects Motion with Unprecedented Sensitivity

By Quantum Server Networks

A team of researchers from the Ningbo Institute of Materials Technology and Engineering (NIMTE), part of the Chinese Academy of Sciences, has unveiled a highly stretchable and conductive polymer foam sensor capable of detecting a wide range of motion with remarkable sensitivity. Their breakthrough, published in Materials Today Physics, represents a significant step forward in flexible electronics, human–robot interaction, and wearable health monitoring devices.

Stretchable polymer foam sensor

Image: The POE/CNS foam sensor with segregated structure. Credit: NIMTE

The Science Behind the Sensor

At the core of this innovation is a polyolefin elastomer (POE) combined with carbon nanostructures (CNS). Using a supercritical CO₂ foaming technique, the researchers engineered a porous, segregated composite that reconstructs the conductive network inside the foam. This unique architecture grants the sensor:

  • Stretchability up to 952.5% strain.
  • An ultra-wide strain response range from 0.5% to 762%.
  • Stable performance over more than 4,000 tensile cycles.
  • High sensitivity and rapid response times.

These features set a new benchmark for piezoresistive strain sensors, which traditionally suffer from electrical failure or structural damage under repeated stretching.

Why This Matters

Piezoresistive foam sensors are increasingly critical for next-generation technologies. Their lightweight, compressible, and reproducible design makes them ideal for:

  • Wearable health monitoring – tracking muscle activity, breathing, or posture.
  • Human–robot interaction – enabling soft robotics with tactile sensing.
  • Motion tracking – capturing fine-grained movements for sports science or rehabilitation.
  • Engineering equipment – integrating flexible sensors into industrial machinery and robotics.

By combining eco-friendly production methods with outstanding mechanical and electrical properties, the POE/CNS foam represents a new paradigm in flexible electronics.

A Leap in Flexible Electronics

Traditional porous conductive materials often lose conductivity or break under strain. This novel foam overcomes those limitations by leveraging its segregated microstructure to maintain electrical integrity even under extreme deformation. As a result, it offers both high sensitivity and long-term durability – two qualities essential for real-world applications.

With growing interest in smart textiles, healthcare wearables, and robotic systems, the development of such high-performance polymer foams could open entirely new markets in consumer electronics, medicine, and advanced robotics.

Source: TechXplore (2025)

This blog article was prepared with the assistance of AI technologies.

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#FlexibleElectronics #WearableTech #PolymerFoam #StretchableSensors #Nanotechnology #HumanRobotInteraction #MaterialsScience #SmartTextiles #QuantumServerNetworks #PWmat

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