Stretchable strain sensors with large strain range, high sensitivity, and excellent reliability are of great interest for applications in soft robotics, wearable devices, and structure-monitoring systems. Unlike conventional template lithography-based approaches, 3D-printing can be used to fabricate complex devices in a simple and cost-effective manner. In this paper, we report 3D-printed stretchable strain sensors that embeds a flexible conductive composite material in a hyper-plastic substrate. Three commercially available conductive filaments are explored, among which the conductive thermoplastic polyurethane (ETPU) shows the highest sensitivity (gauge factor of 5), with a working strain range of 0%–20%. The ETPU strain sensor exhibits an interesting behavior where the conductivity increases with the strain. In addition, an experiment for measuring the wind speed is conducted inside a wind tunnel, where the ETPU sensor shows sensitivity to the wind speed beyond 5.6 m/s.

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