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Highly sensitive, wearable and durable strain sensors are vital to the development of health monitoring systems, smart robots and human machine interfaces. The recent sensor fabrication progress is respectable, but it is limited by complexity, low sensitivity and unideal service life. Herein a facile, cost-effective and scalable method is presented for the development of high-performance strain sensors and stretchable conductors based on a composite film consisting of graphene platelets (GnPs) and silicon rubber. Through calculation by the tunneling theory using experimental data, the composite film has demonstrated ideal linear and reproducible sensitivity to tensile strains, which is contributed by the superior piezoresistivity of GnPs having tunable gauge factors 27.7–164.5. The composite sensors fabricated in different days demonstrate pretty similar performance, enabling applications as a health-monitoring device to detect various human motions from finger bending to pulse. They can be used as electronic skin, a vibration sensor and a human-machine interface controller. Stretchable conductors are made by coating and encapsulating GnPs with polydimethyl siloxane to create another composite; this structure allows the conductor to be readily bent and stretched with sufficient mechanical robustness and cyclability. Refereed/Peer-reviewed

Conventional strain sensors based on metals and semiconductors are rigid and cannot measure soft and stretchable objects. Thus, new strain sensors based on polymer/nanomaterial composites are attracting more interest. Although much effort has been dedicated to achieve high values of both sensitivity and stretchability with linearity, this work endeavors to search and establish guidelines for the development of stretchable strain sensors, by critically reviewing conventional sensors and examining recent progress. It starts from introducing key parameters for conventional strain sensors; these parameters are further discussed for their potential impact on new polymer/nanomaterial strain sensors. The work concludes that there are no general benchmarks for conventional strain sensors utilized in industry. From the findings, the authors suggest that stretchable strain sensors should be custom designed and developed to meet particular measurement requirements, in comparison with a generic aim of yielding a sensor with high degrees of stretchability, sensitivity, and linearity. Challenges are discussed, including reliability, calibration to be used as proper gauges, and soft data acquisition systems Refereed/Peer-reviewed