High-Performance Flexible Pressure Sensor Array via Screen-Printing With Enhanced Sensitivity and Low Crosstalk

The rapid development of wearable electronics and robotics has created a demand for high-resolution, low-crosstalk pressure-sensing arrays. Traditional methods face challenges such as limited sensitivity, a narrow detection range, and significant crosstalk, requiring complex and costly processes. In this study, an optimized technique for producing a flexible pressure sensor array via screen-printing methods is presented. Through adjustments in printing parameters, a broad sensitivity range was attained, ranging from 11.0 kPa−1 at pressures below 8–0.09 kPa−1 at pressures up to 942 kPa. Moreover, a developed screen-printed isolation with exceptional elasticity and insulation characteristics effectively reduced crosstalk to −11.65 dB. The pressure sensor array achieves a spatial resolution of 1.6 mm and demonstrates stable performance with only a 1.32% resistance fluctuation after 3000 cycles. The sensor was integrated into a pressure detection system for monitoring oral tongue pressure and swallowing pressure, highlighting its potential for medical applications.