A porous elastomer with a cavity array for three-dimensional plantar force sensing

Human gait is an important indicator for diagnosis of various movement-related disorders. Three-dimensional (3D) plantar force monitoring enables real-time recording of contact forces in both the normal and tangential directions in each step, providing useful clues for identification of irregular gait patterns or gait-related health issues. Most flexible sensors for gait monitoring focus on contact forces in the normal direction, being limited to detect forces in the tangential direction. Herein we have developed a porous elastomer with a cavity array (PECA) to measure 3D contact forces for gait analysis. The sensor consists of two fabric electrodes and a dielectric layer of porous Ecoflex elastomer containing a 5 × 5 cavity array, forming four parallel-plate capacitor units in a soft construction. Therefore, a 3D force in any arbitrary direction generates four unique capacitive electrical signals. Importantly, the PECA includes a well-designed combination of micrometer-scale pores and millimeter-sized cavities, dramatically improving the detection sensitivity and linear elasticity range. We have demonstrated high sensitivities of 0.41 N⁻¹ and 0.23 N⁻¹ in the normal and tangential directions, respectively. The flexible PECA-based sensors have been tested to sensitively distinguish various standing postures and different stride lengths for gait analysis, promising reliable translation into areas such as healthcare monitoring, sports training, and rehabilitation engineering.