Recent advances in electrospun fiber-based flexible pressure sensors for next-gen healthcare applications: a review

Abstract

This review thoroughly evaluates the advancements and applications of electrospun functional fiber-based pressure sensors in healthcare diagnostics. Electrospinning is a versatile technique for producing micro- and nanoscale fibers with high surface-to-volume ratios and tunable porosity, making it an excellent platform for highly sensitive, flexible, and wearable sensing structures. The survey focuses on integrating piezoelectric and piezoresistive materials into electrospun fiber mats. These materials are key to transduction mechanisms, converting mechanical pressure stimuli into electrical signals by varying charge or resistance. Key healthcare applications based on pressure are critically evaluated, including wearable vital sign monitors (pulse and respiration), body motion detection for rehabilitation, gait analysis, smart prosthetics, and real-time wound-healing assessment through pressure distribution mapping. Fiber-based sensors offer high sensitivity, lower detection limits, flexibility, biocompatibility, breathability, and adaptability to complex body contours. Findings reveal that the sensitivity of the multilayer sensor (996.7 kPa^-1) is far greater than that of the composite sensor (0.21 kPa^-1), enabling precise detection of pulse and joint movements. Several limitations have also been addressed, including signal stability and durability, ecological interference (including humidity and temperature), scalable manufacturing, and seamless integration with electronics for continuous monitoring. Future research directions are provided for developing novel, multifunctional, and self-powered materials that enhance environmental resilience, scalable fabrication, and wireless data transmission. Finally, it is concluded that electrospun fiber sensors are poised to transform personalized, non-invasive, and continuous health monitoring, advancing next-generation, innovative healthcare systems.

Keywords

Sensors / electrospinning / piezoelectric / piezoresistive / healthcare

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