Magnetically Assisted 3D Printing of Ultra-Antiwear Flexible Sensor

3D printing has shown promise in the development of notable sensing and health detection devices. Nonetheless, challenges remain in the concurrent development of highly durable wearable sensors with low-friction surfaces. This challenge serves as a limiting factor in the operational lifespans of these sensors. In this study, a magnetically assisted 3D printing technique is developed to fabricate composites reinforced with magnetic Fe₃O₄@SiO₂ nanochains (NCs) with dimensions of 60.2 µm in length (L) and 0.2 µm in diameter (D), indicating an L:D ratio exceeding 300. By applying a vertical magnetic field and extrusion flow field to the sensor's surface layer, the NCs can be arranged differently (together with the printed textures), reducing the coefficient of friction by 27.7% and improving the wear resistance. This approach is inspired by nacre, known for its impressive durability and resilience. A motion monitoring sensor with an extended lifespan is successfully fabricated by using liquid metal ink integrated with an anti-wear layer. These findings offer significant insights into the evolution of wearable sensors, demonstrating their adaptability to multi-material printing and resulting in improved performance and service lives.