Soft, wearable systems hold promise for a wide variety of new or enhanced applications in the realm of human-computer interaction, physiological monitoring, wear-able robotics, and a host of other human-centric devices. Soft sensor systems have been developed concurrently in order to allow these wearable systems to respond intelligently with their surroundings. A recently reported sensing mechanism based on the strain-mediated contact in anisotropically resistive structures (SCARS) is an attractive solution due to its high sensing resolution, low-profile nature, and high mechanical resilience. Furthermore, the resistance-based output provides a simple electronic readout, facilitating its use in a wide variety of applications. However, previous iterations of the sensing mech-anism have exhibited stress relaxation and hysteretic behaviors that limit the scope of its use. Here, we report an iteration of the SCARS mechanism that uses silicone-based materials with low mechanical loss in order to improve the sensor signal stability and bandwidth. A new fabrication approach is developed which permits the incorporation of a liquid elastomer adhesive layer while also preserving the SCARS sensing functionality. The silicone-based SCARS sensors exhibited fast stress relaxation response (< 1 s) and reduced cyclic drift properties by more than half that of previously reported designs. A physiological monitoring demonstration is presented, validating that the new sensor design is mechanically resilient to such applications and has potential for use in real-world wearable use cases.

Soft strain sensors have been explored as an unobtrusive approach for wearable motion tracking. However, accurate tracking of multi degree-of-freedom (DOF) noncyclic joint movements remains a challenge. This paper presents a soft sensing shirt for tracking shoulder kinematics of both cyclic and random arm movements in 3 DOFs: adduction/abduction, horizontal flexion/extension, and internal/external rotation. The sensing shirt consists of 8 textile-based capacitive strain sensors sewn around the shoulder joint that communicate to a customized readout electronics board through sewn micro-coaxial cables. An optimized sensor design includes passive shielding and demonstrates high linearity and low hysteresis, making it suitable for wearable motion tracking. In a study with a single human subject, we evaluated the tracking capability of the integrated shirt in comparison with a ground truth optical motion capture system. An ensemble-based regression algorithm was implemented in post-processing to estimate joint angles and angular velocities from the strain sensor data. Results demonstrated root mean square errors (RMSEs) less than 4.5° for joint angle estimation and normalized root mean square errors (NRMSEs) less than 4% for joint velocity estimation. Furthermore, we applied a recursive feature elimination (RFE)-based sensor selection analysis to down select the number of sensors for future shirt designs. This sensor selection analysis found that 5 sensors out of 8 were sufficient to generate comparable accuracies.

The development of soft, compliant force sensors is greatly sought after in areas such as soft robotics and prosthetics. Nevertheless, solutions for measuring forces in multiple axes, while being mechanically compliant, have been few and far between. Here we present a compliant sensor able to detect forces tangential and normal to the sensor surface. The transduction mechanism is based on the deformation of laser-machined carbon fiber composite (CFC) micro-scale meanders, encapsulated within elastomers layers. Strains in the elastomer are transmitted to the meanders, causing changes in the electrical resistance of the sensor contact mechanics. Configuring the meanders in a radial pattern, segmenting them into quadrants (two antagonist pairs) and biasing the center of the sensor out-of-plane enables detection of forces in multiple axis via differential measurement. Sensors were manufactured using a custom fabrication process and exhibited high mechanical compliance with a very low form factor. The sensors were experimentally characterized and demonstrated large differential changes in resistance (up to 26 kΩ for tangential forces applied to the sensor surface). We integrated our sensor onto a soft robotic gripper finger and demonstrated the ability to detect changes in friction at the actuator surface, thus demonstrating their potential for real world applications.

Wearable robotic systems which aid or enhance human performance are the subject of substantial ongoing research efforts. Soft exosuits to assist with walking represent one class of system that leverage textiles and apparel to provide a lightweight and nonrestrictive means to interface to the lower extremity and apply assistive joint torques via a cable that applies a force across a biological joint. Current embodiments of the soft exosuit use off-the-shelf load cells attached to the distal end of a Bowden cable to measure and control the delivered force. As these systems evolve, we envision replacing all rigid components with compliant, textile-based components. Here we present a new force sensing concept suitable for exosuit applications. The approach is based on micro-machined carbon fiber composite structures encapsulated in elastomer materials as the transducer element, and high-strength, stiff textiles as the load bearing element. The transduction mechanism uses the Poisson effect in the encapsulating elastomer to create electrical contact between the carbon fiber structures. This method allows the sensor to be sensitive in tension while remaining insensitive to bending deformation. We fabricate a prototype sensor capable of detected forces up to 300 N, yet weighing just 2.15 g. The compliant nature of the materials used in fabrication allow the sensor to be flexible. The sensor output is qualitatively very repeatable, yet exhibits moderate drift at peak load. However this drift begins to stabilize over the test duration. These preliminary results demonstrate the promising potential of this sensor technology for soft exosuit systems.