3D printed architecture sensors

Sensors are devices, modules, machines, or subsystems that convert external stimuli, such as force, pressure, bio-signals, and vibration, into electrical signals. Control and safety systems for automobiles, industrial robots, and medical equipment have been developed using these sensors. There are various types of sensors, each with its own purpose, but each also has inherent limitations that affect the accuracy of the sensor signals and result in errors in control or safety systems. To address these limitations, architectural approaches based on paper art, such as origami and kirigami, have been proposed. These ancient art forms, with their complex geometric features, offer unique mechanical behaviors that can overcome the limitations of conventional sensors. In this thesis, representative architectural approaches to overcome the drawbacks of pressure/force, electrophysiology, and vibration sensors are introduced. This thesis aimed to design 3D-printed origami and kirigami sensors to overcome their fundamental limitations and showcase their unique applications. With the 3D sensors, various applications such as functional and human-interactive humanoid robots, 3D-printed mechanical ventilators, and structural health monitoring systems have been demonstrated. The 3D origami pressure/force sensors were developed based on the origami folding behavior, which minimizes facet deformation during compression. Also, the unique mechanical behaviors of origami folding prevent irregular or permanent deformations of the pressure sensing diaphragm. In addition, 3D Kresling origami dry electrodes were developed for electrophysiological sensors to address contact issues with human skin. Moreover, the shape-programmable properties of the kirigami structure enabled the development of 3D optimized vibration sensors for specific target frequencies, overcoming interference from external noise vibration. Also, their relevant applications show that the structural features of the 3D architecture sensors provide additional benefits for their practical applications beyond overcoming their limitations. In conclusion, this thesis proposes novel strategies for designing and fabricating sensors that can enhance their performance and functionality, thus contributing to the advancement of innovative approaches in sensor technology.