A Multifunctional Flexible Sensor Based on a Hybrid Microstructured Functional Layer

Flexible capacitive sensors for electronic skins and soft robotic systems are expected to provide not only high-pressure sensitivity but also multifunctional sensing capabilities. However, conventional dielectric layer designs often suffer from a trade-off among multiple functionalities. To address this challenge, we developed a flexible sensor featuring a hybrid microstructured functional layer for pressure sensing, distance monitoring, and material identification. The functional layer was a polydimethylsiloxane (PDMS) film embedded with micro-sized sugar particles and patterned with microstructures on its surface. The pressure-sensing performance, such as pressing sensitivity, response time, and hysteresis, was first evaluated. The pressure sensitivity reached 3.55 × 10−2 kPa−1 at an applied force of 1 N, which is significantly greater than that of the sensor using either a flat PDMS layer or a PDMS film embedded solely with sugar particles. The hybrid microstructured sensor also exhibited superior performance in terms of hysteresis and repeatability. Moreover, the sensor was shown to measure the distance to an object with a sensitivity of 0.023 mm−1. Furthermore, the robust identification of materials with different permittivities was demonstrated using the flexible sensor. Given its multifunctional, non-contact, and high-sensitivity capabilities, this flexible sensor holds significant potential for integration into advanced electronic skins, intelligent soft robotics for tactile object sorting, and human–-machine interfaces.