![]() The sensor’s fast production speed, high productivity, simple design, low cost, stability, and lower restrictions on the surface morphology of the substrate mean it has wider application prospects. In this study, a wireless screen-printable flexible strain sensor system based on an Ag/MWCNT composite was designed for wind sensing. In particular, the calculation of strain energy via the piezo resistance and applied load plays a key role in this study. However, the sensing mechanism is still poorly understood. On the other hand, simulations are being used in various fields to analyze specific phenomena. ![]() Thus, the fabrication of wireless sensors with a wireless communication channel is preferred and expected to offer unique advantages, such as installation flexibility, reduced weight, improved sensor density, and ease of maintenance. ![]() Conventionally, strain sensor networks require wires to connect each individual strain sensor to a centralized data acquisition unit however, this causes measurement limitations, high maintenance costs, and reductions in spatial resolution. A previous study physically mixed CNTs with silver particles, while another using chemical methods produced AgNP-modified CNTs, resulting in improved electrical properties and a high gauge factor (GF) sensitivity with the results being two times better than for CNTs. To make up for certain defects that carbon base materials often suffer from, such as low conductivity (sheet resistance of ≈4 KΩ sq −15) and relatively low sensitivity, researchers have mixed CNTs with other metal materials. Carbon nanotubes (CNTs) have been broadly used in strain sensors as conductive materials due to their excellent mechanical properties, chemical inertness, and low cost. When applying printed flexible strain sensors for wind sensing, the conductive material is an important component, since it mainly determines the sensing properties. However, the screen printing process has not been applied for wind sensing applications in various fields. Alternatively, screen printing is the most widely used process for the fabrication of flexible strain sensors because of its advantages of fast production, massive productivity, easy design, and less limited surface morphology of the substrates. However, due to the nature of the FDM printing process, the low printing speeds and limited productivity are still problematic. The printing process can be modeled so that core and adjustable design aspects can be fitted to specific wind sensing applications. In this previous work, conductive polylactic acid was printed on a flexible substrate via the fused deposition method. ![]() To avoid these defects, a low-cost, low-complexity, powerful wind direction sensor using 3D printed flexible strain sensor has been demonstrated. Although this approach can provide accurate wind velocity measurements, the tubes are prone to clogging by water droplets and ice crystals. Another measuring mechanism includes the use of a pressure anemometer, which works based on the measurement of barometric pressure proportional to the square of the wind velocity. However, these mechanisms have detection thresholds due to mechanical wear, performance degradation, and bearing friction, and are relatively expensive, limiting their use. To measure wind velocity, traditional measuring mechanisms are widely used, such as vane and cup anemometers and acoustic anemometers. Wind sensing has been utilized in various fields, including in the determination of drying rates, pollen propagation, pathogen propagation, air conditioning strategy design, and wind turbine operations. In an application based on an IoT system, we verified that the response of the wireless sensor corresponded with that of a wired sensor, indicating the expansion of low-cost, mass-produced screen-printed wind sensors. In addition, the sensor showed 98% temperature sensitivity during a wind sensing test due to the intrinsic properties of the metal hybrid composite. After confirming the suitability for screen printing, we investigated the performance of the printed strain sensor, obtaining a gauge factor (G.F.) of 2.08 with 90% sensitivity and high durability after 6000 bending cycles. To achieve high printability with the metal hybrid composite for the fabrication of a screen-printed flexible sensor, we systematically investigated the rheological properties, resulting in the high shear thinning and thixotropic behavior of the composite. In this study, we demonstrated a wireless screen-printable flexible strain sensor system based on Ag/MWCNT composite for wind sensing. Wind sensing has become a key component in various fields with the growing trend of assessing air conditions for energy conversion.
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