Innovative Multi-Microchannel Design for Enhanced Sensitivity in Soft Microfluidic Force Sensors

Microfluidic-based sensors are rapidly gaining momentum in the field of soft tactile sensing, especially for the precise measurement of externally applied forces. This study introduces an innovative “multi-microchannel” design for soft microfluidic force sensors, enhancing the sensitivity while extending the working range. Our optimized fabrication protocol combines 3D printing and soft lithography technologies to create silicone elastomeric layers that form the sensor, offering a scalable, cost-effective approach suitable for standard laboratory settings. Fabricated sensors exhibit inherent flexibility, enabling them to stretch, twist, and bend. Our findings highlight the significant impact of microchannel characteristics, such as cross-sectional area and depth, on force sensing performance. We demonstrated the effectiveness of our novel multi-micro channel sensing approach by integrating two distinct micro channels at varying depths within a single sensor, providing dual force sensing profiles. Overall, microfluidic force sensing emerges as a key enabling technology for soft tactile sensing applications, including soft robotics and wearables.