Extreme‐Temperature Resistant, Flexible, and Sensitive Strain Sensor for Aerospace Parachute Deployment

ABSTRACT Flexible strain sensors are increasingly used in soft robotics, human–computer interaction, motion monitoring, and medical treatments. Strain sensors can also play a critical and life‐saving role in aerospace applications by enhancing safety, reliability, and performance. However, their application in aerospace remains limited due to challenges with compatibility and reduced functionality under extreme environmental and mechanical stress conditions. The primary challenge lies in developing lightweight, flexible sensors with high sensitivity that can operate accurately in harsh environments, including extreme temperatures. This study introduces a resistive strain sensor utilizing single‐walled carbon nanotubes (SWCNTs) as the sensing material, shielded with an ultraviolet (UV) resin layer. The developed sensor sets a new benchmark in performance, achieving a high sensitivity of 38.75 at a minimum bending radius of just 1 mm (7.52% maximum strain) with a rapid response time of only 120 ms. Unlike conventional counterparts, it combines outstanding durability and repeatability, enduring over 3000 bending cycles without degradation, while maintaining stable performance under extreme conditions from –50 to 125°C. This unique integration of ultra‐high sensitivity, mechanical robustness, fast response, and wide temperature resilience makes the sensor best‐in‐class for demanding aerospace applications. To validate its practical utility, the sensor was integrated into a model parachute deployment detection system, demonstrating exceptional resilience under high strain and extreme environmental conditions.