Abstract
Constrained by materials, structures, and interface, achieving high sensitivity, wide strain range, and linearity simultaneously remains an impossible triangle for flexible sensors. Herein, we propose 3D super-interface strategy based on patterned rubber substrate-conductive crack layer, successfully developing a microcrack super-interface flexible sensor (MSFS) with ultra-sensitivity (0–10% strain, GF 1.1 × 10⁸ and linearity 0.98). The 3D super-interface relies on the synergistic micro/nano level physical anchoring, and hydrogen bonding interfacial interactions between the rubber matrix and conductive crack layer, achieving strong interlayer bonding. During the sensing process, the crack structure endows the sensor ultra-sensitivity within 0–10% strain range; while the 3D super-interface ensures continuous electrical conductivity under >50% strain conditions. MSFS holds potential application value in monitoring expansion in silicon anode batteries. When the battery expansion reaches 2%, its resistance change can be as high as 22-fold. This approach enables the customized design of flexible sensors for ultra-sensitivity applications.
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All data generated or analysed during this study are included in this published article (and its supplementary information files). Source data are available on Figshare at https://doi.org/10.6084/m9.figshare.30827915.
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This work is primarily supported by Yukun Chen’s personal funds and resources.
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X.W., Y.H., and Y.C. conceived the idea and data analysis. X.W. wrote the first paper. S.Y. helped with SEM testing. H.W. provided the SWCNT. X.W. conducted the majority of the experiments. C.X, Z.W., and Y.C. supervised the research, with guidance. X.W., C.X., and Y.C. revised the manuscript. All authors reviewed and commented on the paper.
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Wang, X., Huang, Y., Wang, H. et al. A rubber-based sensor with over 100 million-level ultra-sensitivity (0–10% strain range) via 3D super-interface. Nat Commun (2026). https://doi.org/10.1038/s41467-026-70434-y
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DOI: https://doi.org/10.1038/s41467-026-70434-y
