Recent advances in porous polymer-based flexible piezoresistive pressure sensors

Abstract

With the rapid development of wearable devices and intelligent human–machine interaction technologies, the demand for high-precision pressure sensors has soared. Piezoresistive pressure sensors excel due to their simple structure, low cost, and high sensitivity, among which flexible piezoresistive pressure sensors based on porous polymers have become a research focus, thanks to their unique 3D porous structure and excellent performance. This review summarizes recent advances: it introduces key performance metrics and the piezoresistive sensing mechanism; outlines porous structure preparation methods (phase separation, 3D printing, electrospinning) with their principles, advantages, and limitations; examines conductive fillers (carbon-based, polymer, metal, MXene) with their properties and applications; and highlights flexible substrates (silicone, polyurethane, polyimide, natural polymers) in ensuring mechanical compliance and device integration. Studies show material innovation, structural optimization, and process improvement can significantly enhance sensor accuracy, stability, and durability, helping break traditional performance bottlenecks. Future prospects are broad in tactile sensing, biomedical monitoring, and human–machine interaction, providing references for related research and industrial development.