Yu, J; Kariyawasam, H; Wu, S; Subramanian, S; Withana, A; (2025) Designing Multi-DoF Epidermal Bend Sensors Using Flexible Resistive Traces. IEEE Sensors Journal 10.1109/JSEN.2025.3623068. (In press).

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Abstract

We present a single-layer resistive epidermal bend sensor that senses four degrees of freedom (DoF) via combinatorial port connections within a unified pattern, avoiding multi-sensor arrays. We instantiate and compare four patterns (square-like, tree-like, arc-like, and honeycomb-like) under a common single-layer measurement strategy; we present modeling for the straight layout and empirical analyses for the others. With a 15:100 carbon-to-gel composite and a 0.3 mm conductive layer after 20% pre-strain, the material exhibits hysteresis of 0.6% and an average gauge factor magnitude of 0.6. The proposed design is thin, flexible, and conforms comfortably to the skin. Across test sets, 95.4% of angle estimates fall within ±2.798° of ground truth. Our approach utilizes cost-effective materials and accessible fabrication techniques. This paper demonstrates the potential of our method for various applications in epidermal sensing. We envision that the proposed resistive patterns will help designers create accurate, conformal, and multi-DoF sensors.

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