3D printed microstructured ultra-sensitive pressure sensors based on microgel-reinforced double network hydrogels for biomechanical applications

Hydrogel-based wearable flexible pressure sensors have great promise in human health and motion monitoring. However, it remains a great challenge to significantly improve the toughness, sensitivity and stability of hydrogel sensors. Here, we demonstrate the fabrication of hierarchically structured hydrogel sensors by 3D printing microgel-reinforced double network (MRDN) hydrogels to achieve both very high sensitivity and mechanical toughness. Polyelectrolyte microgels are used as building blocks, which are interpenetrated with a second network, to construct super tough hydrogels. The obtained hydrogels show a tensile strength of 1.61 MPa, and a fracture toughness of 5.08 MJ m-3 with high water content. The MRDN hydrogel precursors exhibit reversible gel-sol transitions, and serve as ideal inks for 3D printing microstructured sensor arrays with high fidelity and precision. The microstructured hydrogel sensors show an ultra-high sensitivity of 0.925 kPa-1, more than 50 times that of plain hydrogel sensors. The hydrogel sensors are assembled as an array onto a shoe-pad to monitor foot biomechanics during gaiting. Moreover, a sensor array with a well-arranged spatial distribution of sensor pixels with different microstructures and sensitivities is fabricated to track the trajectory of a crawling tortoise. Such hydrogel sensors have promising application in flexible wearable electronic devices.