Mesh-Architected Structurally Flexible Pb(Zr0.52Ti0.48)O3 Framework Enables Highly Sensitive and Stretchable Piezoelectric Sensors

TL;DR

A new stretchable and sensitive piezoelectric sensor was developed using a mesh-like PZT structure, suitable for wearable health monitoring and robotics.

Contribution

A novel mesh-architected PZT framework enables both high sensitivity and stretchability in piezoelectric sensors.

Findings

The PZT-silicone composite achieved 220% stretchability and 39.57 mV kPa−1 sensitivity.

The sensor can detect subtle surface roughness and monitor large-strain human motion.

It maintains stable performance over 50 stretch-compression cycles with minimal hysteresis (~8.13%).

Abstract

A monolithic, structurally flexible, continuous Pb(Zr0.52Ti0.48)O3 (PZT) piezoelectric fiber was innovatively fabricated through network architecture design.The PZT framework well inherited the macro- and micro-structure of the mesh fabric, endowing the PZT-silicone composite material with high stretchability up to 220%.The developed strain sensor exhibited both high stretchability (100%) and high sensitivity (39.57 mV kPa−1), thus enabling its application in subtle surface roughness perception and large-strain human motion monitoring.

A monolithic, structurally flexible, continuous Pb(Zr0.52Ti0.48)O3 (PZT) piezoelectric fiber was innovatively fabricated through network architecture design.

The PZT framework well inherited the macro- and micro-structure of the mesh fabric, endowing the PZT-silicone composite material with high stretchability up to 220%.

The developed strain sensor exhibited both high stretchability (100%) and high sensitivity (39.57 mV kPa−1), thus enabling its application in subtle surface roughness perception and large-strain human motion monitoring.

The online version contains supplementary material available at 10.1007/s40820-026-02148-1.

The booming demand for flexible electronics requires piezoelectric sensors that can simultaneously deliver high sensitivity and exceptional stretchability, which has become a significant challenge beyond the capabilities of conventional devices. Inspired by the hexagonal mesh structure, we adopted an architecture design to fabricate a continuous, structurally flexible ceramic skeleton, thereby developing a piezoelectric sensor integrating both high sensitivity and superior stretchability. The macroscopic 3D interconnected skeleton ensures efficient stress transfer for enhanced pressure sensitivity, while the hexagonal topology with hierarchical microfibers enables deformation-driven slippage under load to ensure robust stretchability. Consequently, the composite achieves remarkable stretchability (220% strain) and excellent mechanical stability (> 50 stretch-compression cycles, hysteresis ~ 8.13%). The fully flexible piezoelectric sensor maintains stable functionality even under 100% tensile strain and exhibits high sensitivity (39.57 mV kPa−1), collectively outperforming conventional piezoelectric sensors. Based on these unique advantages, we demonstrate the sensor’s capability in fine surface roughness discrimination and real-time monitoring of human stretching movements, highlighting its great potential for applications in robotic dexterous manipulation and wearable health monitoring systems.

The online version contains supplementary material available at 10.1007/s40820-026-02148-1.

Figures