Reham Khalef, Yufan Chen, LI Runchun, Mengdan Zhang, Mahmoud Farghaly, Yanhua Liu, Ao Wang, S. Yan, Xueliang Xiao
It is essential to identify highly robust, flexible capacitive pressure sensors to ensure the sustainable application of wearable electronics, smart fabrics, and soft robots. This research systematically outlines the material and structural improvements that directly reduce mechanical stress and enhance operating durability. We critically evaluate the impact of microstructural engineering, including porous, pyramidal, and wrinkled dielectric layers, on reducing stress concentration and improving cyclic stability. We discuss the application of material composites, such as carbon nanotube/PDMS and graphene/polymer hybrids, in the development of sensors that maintain performance after several thousand compression cycles. Certain bionic and coral-inspired designs show superior durability. It includes durable manufacturing methods such as 3D printing of microstructures and developments that interact with textiles, ensuring durability during large-scale production. A comprehensive review of textile-based sensors emphasizes methods to improve washing durability and mechanical strength in wearable applications. This review establishes a framework for developing the next wave of capacitive sensors that are very sensitive and extremely durable by combining design methods with durability measurements. This will facilitate the transition from laboratory experiments to commercial reality.