Linear Range Enhancement in Flexible Piezoresistive Sensors Enabled by Double‐Layer Corrugated Structure

Abstract

Abstract Flexible pressure sensors, serving as critical components in wearable medical devices, intelligent robotics, and human‐computer interaction, and optimizing their performance remains a key research focus. Despite significant improvements in sensitivity and detection range, most existing sensors still fail to achieve linear responses across broad detection ranges, requiring complex signal processing and thus limiting their widespread application. Inspired by the corrugated paper structure, this study innovatively presents a flexible piezoresistive sensor with a double‐layer corrugated structure, fabricated from a polydimethylsiloxane (PDMS)/multi‐walled carbon nanotubes (MWCNTs) composite. The design achieves efficient pressure distribution and minimizes stress concentration through hierarchical corrugations of differing heights combined with gradient elastic modulus. The sensor exhibits a sensitivity of 1.7 kPa −1 and linear response ( R 2 = 0.998) across an extensive range from 0.002–500 kPa, with response and recovery times of 63/47 ms, and maintains consistent performance even after 6,000 load‐unload cycles. The implementation of wearable electronics and table tennis training guidance based on double‐layer corrugated structure flexible pressure sensors demonstrates effective sensing signal feedback, validating the significant application potential, which provides novel insights for developing piezoresistive sensors with highly linear responses across wide measurement ranges.