| Summary: | Over the years, several bare metal and crack-based strain sensors have been proposed for various fields of science and technology. However, due to their low gauge factor, metal-based strain sensors have limited practical applications. The crack-based strain sensor, on the other hand, demonstrated excellent sensitivity and a high gauge factor. However, the crack-based strain sensor exhibited non-linear behavior at low strains, severely limiting its real-time applications. Generally, the crack-based strain sensors are fabricated by generating cracks by bending a polymer film on which a metal layer has been deposited with a constant curvature. However, the random formation of cracks produces nonlinear behavior in the crack sensors. To overcome the limitations of the current state of the art, we propose a V-groove-based metal strain sensor for human motion monitoring and Morse code generation. The V-groove crack-based strain sensor is fabricated on polyurethane acrylate (PUA) using the modified photolithography technique. During the procedure, a V-groove pattern formed on the surface of the sensor, and a uniform crack formed over the entire surface by concentrating stress along the groove. To improve the sensitivity and selectivity of the sensor, we generated the cracks in a controlled direction. The proposed strain sensor exhibited high sensitivity and excellent fidelity compared to the other reported metal strain sensors. The gauge factor of the proposed V-groove-induced crack sensor is 10-fold higher than the gauge factor of the reported metal strain sensors. In addition, the fabricated V-groove-based strain sensor exhibited rapid response and recovery times. The practical feasibility of the proposed V-groove-induced crack-based strain sensor is demonstrated through human motion monitoring and the generation of Morse code. The proposed V-groove crack sensor can detect multiple motions in a variety of human activities and is anticipated to be utilized in several applications due to its high durability and reproducibility.
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