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The purpose of this paper is to deal with an identification of a novel ink-jet printing sensor fabrication technology for fabricating flexible carbon heaters of macro and micro sizes, carbon interdigitated (IDT) electrodes and silver IDT electrodes. The technology involved in the proposed ink-jet printing method and materials used for the formulation of homemade nano-conductive inks (digital inks) are discussed in detail. The ink-jet printed flexible carbon heaters of different sizes (macro and micro) and carbon IDT electrodes and flexible silver IDT electrodes can be used as the flexible sensing layers in electrochemical gas sensors for sensitive and selective gas sensing applications. The characterization of ink-jet printed carbon heaters on Kapton substrate and its results are discussed. Similarly, the results of formulation of silver nano-conductive ink and printing of silver IDT electrodes on Kapton and its characterization are reported here for the first time.

Flexible carbon heaters of different sizes (macro and micro), carbon micro-IDT electrodes and silver IDT electrodes patterns were developed using AutoCAD 2D and printed on the Kapton (polyimide sheet) flexible substrate using the home-made nano-conductive inks with the help of EpsonT60 commercial piezo-head-based drop-on demand technology printer with standard printing options.

The proposed novel method is able to print heater patterns and IDT electrode patterns of approximately 12 µm and approximately 1 µm thickness, respectively, on flexible substrate using the home-made nano-conductive inks of carbon and silver by using a commercial low-cost printer. The home-made nano-conductive inks can be re-used for multiple prints up to six months shelf life. The resistance of the carbon heater was measured as 88 O under normal atmospheric condition. The novel flexible carbon heater was tested for its functionality and found to be satisfactory. The resistance of the silver IDT flexible electrodes was measured as 9.5 O which is better than the earlier works carried out in this paper.

The main challenge is associated with cleaning of printing ink ejection system in the existing commercial printers. The customization of the existing printer in the near future can minimize the printing challenges.

The novel ink-jet printing technology proposed in this work is cost-effective, capable of achieving bulk production of flexible sensor elements, and consumes the least device fabrication time and high material yielding. The printing can be done with commercial piezo-head-based ink-jet printers with custom-prepared nano-conductive inks. There is a huge market potential for this paper.

Both the carbon heaters and silver IDT electrodes were printed on Kapton flexible substrate by using the commercial printer for the first time. The paper is promising the revolution in flexible low-cost sensor fabrication for mass production, and it is an alternate for thin film and thick sensor fabrication methods. The future of sensor fabrication technology will be the ink-jet printing method. In this paper, the research developments of flexible carbon heaters and flexible silver IDT electrodes for the time are reported. The characterization of carbon heaters and silver IDT electrodes were carried out and confirmed that the results are favourable for gas sensor applications.

The purpose of this research is to propose a flexible sensor with a weft-knitted float stitch structure and to explore knitting techniques that allow conductive yarns to be skin-tight and less exposed, reducing production processes and increasing productivity. Study its electrical conductivity in different yarn materials, knit processes and deformation ranges. The analysis is compared to provide some basis for the design of the electrodes.

The method includes five operations: (1) Analysis of the morphological appearance, tensile variation, fiber material properties and electrical conductivity of high-elastic and filament silver-plated conductive yarns. (2) Based on the knitting process of the floating yarn structure, three-dimensional modeling of the flexible sensor was carried out to explore the influence of knitting process changes on appearance characteristics. (3) The fabric samples are knitted by different silver-plated conductive yarns with different structures. Processing of experimental samples to finished size by advance shrinkage. (4) Measure the resistance of the experimental sample after the machine has been lowered and after pre-shrinking. Use the stretching machine to simulate a wearing experiment and measure the change in resistance of the sample in the 0–15% stretching range. (5) Analyze the influence factors on the conductive performance of the flexible sensor to determine whether it is suitable for textile flexible sensors.

For the float knitted flexible sensors, the floating wire projection is influenced by the elasticity of the fabric and the length of the floating wire. Compared to the plain knitted flexible sensors, it has less resistance variation and better electrical properties, making it suitable for making electrodes for textile structures. In addition, the knitting method is integrated with the intelligent monitoring clothing, which saves the process for the integration of the flexible sensor, realizes positioning and fixed-point knitting.

The sensor technology of the designed weft-knitted float structure is varied and can be freely combined and designed in a wide range. Within the good electrical conductivity, the flexible sensor can realize integrated knitting, positioning monitoring, integrating into the appearance of clothing. It can also focus on the wearing experience of wearable products so that the appearance of the monitoring clothing is close to the clothes we wear in our daily life.

In this paper, an integrated positioning knitting flexible sensor based on the weft knitting float structure is studied. The improved knitting process allows the sensing contact surface to be close to the skin and reduces the integration process. The relationship between the exposure of the silver-plated yarn on the clothing surface and the electrical conductivity is analyzed. Within a certain conductive performance, reduces the exposed area of the conductive yarn on the clothing surface and proposes a design reference for the flexible sensor appearance.

Sensing technology has been extensively researched and used due to its applications in industrial production and daily life. Due to inherent limitations of conventional silicon-based technology, researchers are now-a-days paying more attention to flexible electronics to design low-cost, high-sensitivity devices. This observational and analytical study aims to emphasis on carbon monoxide gas sensor. This review also focuses the challenges faced by flexible devices, offers the most recent research on paper-based gas sensors and pays special focus on various sensing materials and fabrication techniques.

To get the better insight into opportunities for future improvement, a number of research papers based on sensors were studied and realized the need to design carbon monoxide gas sensor. A number of parameters were then gone through to decide the flexibility parameter to be considered for design purposes. This review also focuses on the challenges faced by flexible devices and how they can be overcome.

It has been shown that carbon monoxide gas, being most contaminated gas, needs to be fabricated to sense low concentration at room temperature, considering flexibility as an important parameter. Regarding this parameter, some tests must be done to test whether the structure sustains or degrades after bending. The parameters required to perform bending are also described.

Due to inherent limitations of conventional silicon-based technology, now-a-days attention is paid towards flexible electronics to design low-cost, high-sensitivity devices. A number of research articles are provided in the literature concerning gas sensing for different applications using several sensing principles. This study aims to provide a comprehensive overview of recent developments in carbon monoxide gas sensors along with the design possibilities for flexible paper-based gas sensors. All the aspects have been taken into consideration for the fabrication, starting with paper characterization techniques, various sensing materials, manufacturing methodologies, challenges in the fabrication of flexible devices and effects of bending and humidity on the sensing performance.

This paper aims to concentrate on recent innovations in flexible wearable sensor technology tailored for monitoring vital signals within the contexts of wearable sensors and systems developed specifically for monitoring health and fitness metrics.

In recent decades, wearable sensors for monitoring vital signals in sports and health have advanced greatly. Vital signals include electrocardiogram, electroencephalogram, electromyography, inertial data, body motions, cardiac rate and bodily fluids like blood and sweating, making them a good choice for sensing devices.

This report reviewed reputable journal articles on wearable sensors for vital signal monitoring, focusing on multimode and integrated multi-dimensional capabilities like structure, accuracy and nature of the devices, which may offer a more versatile and comprehensive solution.

The paper provides essential information on the present obstacles and challenges in this domain and provide a glimpse into the future directions of wearable sensors for the detection of these crucial signals. Importantly, it is evident that the integration of modern fabricating techniques, stretchable electronic devices, the Internet of Things and the application of artificial intelligence algorithms has significantly improved the capacity to efficiently monitor and leverage these signals for human health monitoring, including disease prediction.

Tactile sensation is an important sensory function for robots in contact with the external environment. To better acquire tactile information about objects, this paper aims to propose a three-layer structure of the interdigital flexible tactile sensor.

The sensor consists of a bottom electrode layer, a middle pressure-sensitive layer and a top indenter layer. First, the pressure sensitive material, structure design, fabrication process and circuit design of the sensor are introduced. Then, the calibration and performance test of the designed sensor is carried out. Four functions are used to fit and calibrate the relationship between the output voltage of the sensor and the contact force. Finally, the contact force sensing test of different weight objects and the flexible test of the sensor are carried out.

The performance test results show that the sensitivity of the sensor is 0.93 V/N when it is loaded with 0–3 N and 0.23 V/N when it is loaded with 3–5 N. It shows good repeatability, and the cross-interference between the sensing units is generally low. The contact force sensing test results of different weight objects show that the proposed sensor performs well in contact force. Each part of the sensor is a flexible material, allowing the sensor to achieve bending deformation, so that the sensor can better perceive the contact signs of the grasped object.

The sensor can paste the surface of the paper robot’s gripper to measure the contact force of the grasping object and estimate the contour of the object.

In this paper, a three-layer interdigital flexible tactile sensor is proposed, and the structural parameters of the interdigital electrode are designed to improve the sensitivity and response speed of the sensor. The indenter with three shapes of the prism, square cylinder and hemisphere is preliminarily designed and the prism indenter with better conduction force is selected through finite element analysis, which can concentrate the external force in the sensing area to improve the sensitivity. The sensor designed in this paper can realize the measurement of contact force, which provides a certain reference for the field of robot tactile.

The purpose of this study was to develop flexible sensors for detection of different concentrations of bacteria, such as Pseudomonas aeruginosa and Staphylococcus aureus, in saline.

The sensors were fabricated using ink-jet printing technology and they consist of a pair of silver interdigitated electrodes printed on mechanically flexible substrates – foil and paper. In house measurement setup for testing and characterization of sensors has been developed. Structural, electrical and mechanical properties of flexible sensors have been determined and compared.

The characteristics of sensor – the resonant frequency as a function of different concentrations of each bacteria – are presented. The obtained results demonstrate different resonant frequencies for each dilution of Pseudomonas aeruginosa and Staphylococcus aureus in physiological saline.

Both sensors showed accurate measurements of bacterial count, which can be achieved with detection of resonant frequency, and this is reflective of the number of bacterial cells within a sample.

The findings suggest that the newly developed method based on measuring resonant frequency corresponds well with bacterial cell count, thus establishing a new proof-of-concept that such method can have significant applications in bacterial cell counting that are economic and easily maintained.

Fast, cost-effective, accurate and non-invasive method for detection of different bacteria from saline was developed.

For the first time, comparison between performances of flexible sensors on foil and paper for bacteria detection is demonstrated. Almost linear dependence between shift of resonant frequency of developed sensors and concentration of bacteria has been obtained.

This review paper aims to introduce the inkjet printing as a tool for fabrication of flexible/wearable sensors. It summarizes inkjet printing techniques including various modes of operation, commonly used substrates and inks, commercially available inkjet printers and variables affecting the printing process. More focus is on the drop-on-demand printing mode, a strongly considered printing technique for patterning conductive lines on flexible and stretchable substrates. As inkjet-printed patterns are influenced by various variables related to its conductivity, resistivity, durability and dimensions of printed patterns, the main printing parameters (e.g. printing multilayers, inks sintering, surface treatment, cartridge specifications and printing process parameters) are reported. The embedded approaches of adding electronic components (e.g. surface-mounted and optoelectronic devices) to the stretchable circuit are also included.

In this paper, inkjet printing techniques for fabrication of flexible/stretchable circuits will be reviewed. Specifically, the various modes of operation, commonly used substrates and inks and variables affecting the printing process will be presented. Next, examples of inkjet-printed electronic devices will be demonstrated. These devices will be compared to their rigid counterpart in terms of ease of implementation and electrical behavior for wearable sensor applications. Finally, a summary of key findings and future research opportunities will be presented.

In conclusion, it is evident that the technology of inkjet printing is becoming a competitor to traditional lithography fabrication techniques, as it has the advantage of being low cost and less complex. In particular, this technique has demonstrated great capabilities in the area of flexible/stretchable electronics and sensors. Various inkjet printing methods have been presented with emphasis on their principle of operation and their commercial availability. In addition, the components of a general inkjet printing process have been discussed in details. Several factors affect the resulting printed patterns in terms of conductivity, resistivity, durability and geometry.

The paper focuses on flexible/stretchable optoelectronic devices which could be implemented in stretchable circuits. Furthermore, the importance and challenges related to printing highly conductive and highly stretchable lines, as well as reliable electronic devices, and interfacing them with external circuitry for power transmission, data acquisition and signal conditioning have been highlighted and discussed. Although several fabrication techniques have been recently developed to allow patterning conductive lines on a rubber substrate, the fabrication of fully stretchable wearable sensors remains limited which needs future research in this area for the advancement of wearable sensors.

The pressure sensors can convert external pressure or mechanical deformation into electrical power and signal, which cannot only detect pressure or strain changes but also harvest energy as a self-powered sensor. This study aims to develop a self-powered flexible pressure sensor based on regular nanopatterned polymer films.

In this paper, the self-powered flexible pressure sensor is mainly composed of two nanopatterned polymer films and one conductive electrode layer between them, which is a sandwich structure. The regular nanostructures increase the film roughness and contact area to enhance the friction effect. To enhance the performance of the pressure sensor, different nanostructures on soft polymer sensitive layers are fabricated using UV nanoimprint lithography to generate more triboelectric charges.

Finally, the self-powered flexible pressure sensor is prepared, which consists of sub-200 nm resolution regular nanostructures on the surface of the elastic layer and an indium tin oxide electrode thin film. By converting the friction mechanical energy into electrical power, a maximum power of 423.8 mW/m2 and the sensitivity of 0.8 V/kPa at a frequency of 5 Hz are obtained, which proves the excellent sensing performance of the sensor.

The acquired electrical power and pressure signal by the sensor would be processed in the signal process circuit, which is capable of immediately and sustainably driving the highly integrated self-powered sensor system. Results of the experiments show that this new pressure sensor is a potential method for personal pressure monitoring, featured as being wearable, cost-effective, non-invasive and user-friendly.

This paper aims to encompass the technological advancements in the area of flexible sensing electronics fabrication particularly for wearable device development applications. In the recent past, it is evident that there is a tremendous growth in the field of flexible electronics and sensors fabrication technologies all around the world. Even though, there is a significant amount of research has been carried in the past decade, but still there is a huge need for exploring novel materials for low temperature processing, optimized printing methods and customized printing devices with accurate feature control.

The author has done an extensive literature survey in the proposed area and found that the researchers are showing significant interest in exploring novel materials, new conductive ink processing methods suitable for additive manufacturing, and fabrication technologies for developing the plastic substrate-based flexible electronics for the on growing demands of wearable devices in the market.

The author has consolidated some of the recent advancements in the area of flexible sensing electronics using the inkjet-printing platform carried out by the researchers. The novel customized inkjet-printing technology, materials selections for device development, compatibility of the materials for the inkjet-printing process and the interesting results of the devices fabricated are highlighted in this paper.

The author has reported the novel inkjet-printing platforms explored by researchers in the recent past for various applications which primarily includes gas sensing. The author has consolidated in a crisp manner about the technology, materials compatible for inkjet-printing, and the exciting results of the printed devices. The author has reported the advantages and challenges of the proposed methods by the researchers. This work will bridge the technical gap in the inkjet-printing technology and will be useful for the researchers to take forward the research work on this domain to the next level.

This paper aims to review the shape sensing techniques using large area flexible electronics (LAFE). Shape perception of humanoid robots using tactile data is mainly focused.

Research papers on different shape sensing methodologies of objects with large area, published in the past 15 years, are reviewed with emphasis on contact-based shape sensors. Fiber optics based shape sensing methodology is discussed for comparison purpose.

LAFE-based shape sensors of humanoid robots incorporating advanced computational data handling techniques such as neural networks and machine learning (ML) algorithms are observed to give results with best resolution in 3D shape reconstruction.

The literature review is limited to shape sensing application either two- or three-dimensional (3D) LAFE. Optical shape sensing is briefly discussed which is widely used for small area. Optical scanners provide the best 3D shape reconstruction in the noncontact-based shape sensing; here this paper focuses only on contact-based shape sensing.

Contact-based shape sensing using polymer nanocomposites is a very economical solution as compared to optical 3D scanners. Although optical 3D scanners can provide a high resolution and fast scan of the 3D shape of the object, they require line of sight and complex image reconstruction algorithms. Using LAFE larger objects can be scanned with ML and basic electronic circuitory, which reduces the price hugely.

LAFE can be used as a wearable sensor to monitor critical biological parameters. They can be used to detect shape of large body parts and aid in designing prosthetic devices. Tactile sensing in humanoid robots is accomplished by electronic skin of the robot which is a prime example of human–machine interface at workplace.

This paper reviews a unique feature of LAFE in shape sensing of large area objects. It provides insights from mechanical, electrical, hardware and software perspective in the sensor design. The most suitable approach for large object shape sensing using LAFE is also suggested.