A Three-Dimensional Surface-Adaptive Stretchable Sensor for Online Monitoring of Composite Materials Curing

Recently, rigid sensors have been commonly applied to online monitoring of the core curing processes of composite materials to prevent both overcuring and under-curing. However, conventional rigid sensors are prone to causing cracks and bubbles in composite materials during the curing process, thereby affecting both the mechanical performance and the overall reliability of the materials. Herein, stretchable interdigital dielectric sensors with flexible substrates and electrodes are designed to conform to complex 3D surfaces, thus enabling embedded nondestructive monitoring of composite curing processes. The sensors obtained can endure 1000 cycles of bending from 0° to 180° and 1000 cycles of stretching at 30% strain while still conforming perfectly to complex 3D surfaces, thus overcoming the inability of traditional curing monitoring sensors to bend. Additionally, sensor integration with an electronic circuit enables real-time data collection and transmission, which makes the device more portable, compact, and lightweight. Moreover, after atmospheric exposure for 5 months, the unit sensitivity of the sensor decreased by only 0.1%, thus demonstrating its excellent reliability and stability. Furthermore, during curing monitoring of the complex three-dimensional surfaces of the Fendouzhe deep-sea submersible, the unit’s sensitivity is close to that of conventional planar monitoring equipment, decreasing by only 0.4%. The proposed online nondestructive monitoring technology demonstrates high sensitivity, high monitoring accuracy, and high reliability during surface monitoring, thus enabling long-term curing monitoring under complex nonplanar conditions.