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Additive Manufacturing of Stretchable Strain Sensors: Fabrication, Optimization and Application
In this project, a novel strain sensor design is fabricated employing different additive manufacturing techniques. The spring sensor's primary material is PLA-Like resin with a nanocomposite encapsulation layer as the functional material. The main principle of Straining the sensors results in a chan...
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2023
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| _version_ | 1867613422231748608 |
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| access_status_str | Open Access |
| author | Bastawrous, John Nady Shihat |
| author_browse | Bastawrous, John Nady Shihat |
| author_facet | Bastawrous, John Nady Shihat |
| author_sort | Bastawrous, John Nady Shihat |
| collection | Thesis |
| description | In this project, a novel strain sensor design is fabricated employing different additive manufacturing techniques. The spring sensor's primary material is PLA-Like resin with a nanocomposite encapsulation layer as the functional material. The main principle of Straining the sensors results in a change in resistivity as the distances among the conductive carbon particles change according to the strain applied.
Sensor fabrication consists of two parts: spring manufacturing and development of nanocomposite encapsulation The nanocomposite matrix is developed through the dispersion of Graphene and Carbon nanotubes in Thermoplastic Polyurethane through sonication and magnetic hotplate stirring. While the spring itself is manufactured by injection molding, the spring is dip-coated in the TPU-Carbon nanocomposite to fully develop the functional spring sensor. The novel sensor design, nanocomposite development, and fabrication processes optimization combine to maximize key performance indicators which are: high gauge factors and large extension percentages. This project reports a maximum gauge factor of 950 and an extension of 300% of the initial sensor length. These promising electrotechnical properties show great potential to be employed in numerous applications, in this report, respiration monitoring for preterm infants is discussed as the main challenge to be addressed. Wearable sensors for infant respiration monitoring face some challenges with low gauge factors and stretchability. The application of this sensor addresses the current problems in the electromechanical behavior of current wearable systems reported in the literature. |
| format | Thesis |
| id | oai:fount.aucegypt.edu:etds-3106 |
| institution | American University in Cairo (Egypt) |
| last_indexed | 2026-06-10T12:35:53.165Z |
| license_str | Not specified — see source repository |
| provenance_str_mv | Harvested via OAI-PMH from AUC Knowledge Fountain — bepress |
| publishDate | 2023 |
| publishDateRange | 2023 |
| publishDateSort | 2023 |
| publisher | AUC Knowledge Fountain |
| publisherStr | AUC Knowledge Fountain |
| record_format | dspace |
| source_str | AUC Knowledge Fountain — bepress |
| spelling | oai:fount.aucegypt.edu:etds-3106 Additive Manufacturing of Stretchable Strain Sensors: Fabrication, Optimization and Application Bastawrous, John Nady Shihat In this project, a novel strain sensor design is fabricated employing different additive manufacturing techniques. The spring sensor's primary material is PLA-Like resin with a nanocomposite encapsulation layer as the functional material. The main principle of Straining the sensors results in a change in resistivity as the distances among the conductive carbon particles change according to the strain applied. Sensor fabrication consists of two parts: spring manufacturing and development of nanocomposite encapsulation The nanocomposite matrix is developed through the dispersion of Graphene and Carbon nanotubes in Thermoplastic Polyurethane through sonication and magnetic hotplate stirring. While the spring itself is manufactured by injection molding, the spring is dip-coated in the TPU-Carbon nanocomposite to fully develop the functional spring sensor. The novel sensor design, nanocomposite development, and fabrication processes optimization combine to maximize key performance indicators which are: high gauge factors and large extension percentages. This project reports a maximum gauge factor of 950 and an extension of 300% of the initial sensor length. These promising electrotechnical properties show great potential to be employed in numerous applications, in this report, respiration monitoring for preterm infants is discussed as the main challenge to be addressed. Wearable sensors for infant respiration monitoring face some challenges with low gauge factors and stretchability. The application of this sensor addresses the current problems in the electromechanical behavior of current wearable systems reported in the literature. 2023-06-15T07:00:00Z thesis application/pdf https://fount.aucegypt.edu/etds/2073 https://fount.aucegypt.edu/context/etds/article/3106/viewcontent/John_Nady_Bastawrous_Thesis.pdf Theses and Dissertations AUC Knowledge Fountain Wearable Strain Sensor Additive Manufacturing Carbon Percolation threshold Nanocomposites TPU polymer 3d Printing Manufacturing Materials Science and Engineering |
| spellingShingle | Wearable Strain Sensor Additive Manufacturing Carbon Percolation threshold Nanocomposites TPU polymer 3d Printing Manufacturing Materials Science and Engineering Bastawrous, John Nady Shihat Additive Manufacturing of Stretchable Strain Sensors: Fabrication, Optimization and Application |
| title | Additive Manufacturing of Stretchable Strain Sensors: Fabrication, Optimization and Application |
| title_full | Additive Manufacturing of Stretchable Strain Sensors: Fabrication, Optimization and Application |
| title_fullStr | Additive Manufacturing of Stretchable Strain Sensors: Fabrication, Optimization and Application |
| title_full_unstemmed | Additive Manufacturing of Stretchable Strain Sensors: Fabrication, Optimization and Application |
| title_short | Additive Manufacturing of Stretchable Strain Sensors: Fabrication, Optimization and Application |
| title_sort | additive manufacturing of stretchable strain sensors fabrication optimization and application |
| topic | Wearable Strain Sensor Additive Manufacturing Carbon Percolation threshold Nanocomposites TPU polymer 3d Printing Manufacturing Materials Science and Engineering |
| url | https://fount.aucegypt.edu/etds/2073 https://fount.aucegypt.edu/context/etds/article/3106/viewcontent/John_Nady_Bastawrous_Thesis.pdf |
| work_keys_str_mv | AT bastawrousjohnnadyshihat additivemanufacturingofstretchablestrainsensorsfabricationoptimizationandapplication |