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KAIST Develops Customized Tactile Sensor That Can Detect Light Breath, Pressure and Sound < Photo 1. (From left) Professor Inkyu Park of KAIST Department of Mechanical Engineering (ME), Dr. Jungrak Choi of ETRI, Ph.D. Candidate Donho Lee and M.S. Graduate Chankyu Han of KAIST ME > When a robot grabs an object or a medical device detects a pulse, the tactile sensor is the technology that senses pressure like a fingertip. Existing sensors had disadvantages, such as slow responses or declining accuracy after repeated use, but Korean researchers have succeeded in developing a sensor that can quickly and accurately detect even light breath, pressure, and sound. This sensor can be used across a broad range — from everyday movements to medical diagnostics. KAIST (represented by President Kwang Hyung Lee) announced on the 23rd of June that Professor Inkyu Park’s team from the Department of Mechanical Engineering, through a collaborative research project with the Electronics and Telecommunications Research Institute (ETRI, President Seung Chan Bang ) under the National Research Council of Science & Technology (NST, Chairman Young Sik Kim), has developed an innovative technology that overcomes the structural limitations of existing tactile sensors. The core of this joint research is the implementation of a customized tactile sensor that simultaneously achieves flexibility, precision, and repeatable durability by applying Thermoformed 3D Electronics (T3DE). < Figure 1. Comparative evaluation of soft elastomer–based 3D structure versus thermoforming-based 3D structure in terms of mechanical properties. > In particular, soft elastomer-based sensors (rubber, silicone, etc. — materials that stretch and return to their original shape) have structural problems such as slow response times, high hysteresis*, and creep**, but this new platform operates precisely in diverse environments and overcomes these limitations. *Hysteresis: A phenomenon where the previously applied force or change is retained like a “memory,” so that the same stimulus does not always produce the same result. **Creep: The phenomenon where a material slowly deforms when a force is continuously applied. T3DE sensors are manufactured by precisely forming electrodes on a 2D film, then thermoforming them into a 3D structure under heat and pressure. Specifically, the top electrodes and supporting pillar structures of the sensor are designed to allow the fine-tuning of the mechanical properties for different purposes. By adjusting microstructural parameters — such as the thickness, length, and number of support pillars — the sensor’s Young’s modulus* can be tuned across a broad range of 10 Pa to 1 MPa. This matches the stiffness of biological tissues like skin, muscle, and tendons, making them highly suitable as bio-interface sensors. *Young’s modulus: An index representing a material's stiffness; this research can control this index to match various biological tissues. The newly developed T3DE sensor uses air as a dielectric material to reduce power consumption and demonstrates outstanding performance in sensitivity, response time, thermal stability, and repeatable accuracy. Experimental results showed that the sensor achieved △sensitivity of 5,884 kPa⁻¹, △response time of 0.1 ms (less than one-thousandth of a second), △hysteresis of less than 0.5%, and maintained a repeatable precision of 99.9% or higher even after 5,000 repeated measurements. < Figure 2. Graphic Overview of thermoformed 3D electronics (T3DE) > The research team also constructed a high-resolution 40×70 array, comprising a total of 2,800 densely packed sensors, to visualize the pressure distribution on the sole of the foot in real time during exercise and confirmed the possibility of using the sensor for wrist pulse measurement to assess vascular health. Furthermore, successful results were also achieved in sound-detection experiments at a level comparable to commercial acoustic sensors. In short, the sensor can precisely and quickly measure foot pressure, pulse, and sound, allowing it to be applied in areas such as sports, health, and sound sensing. The T3DE technology was also applied to an augmented-reality(AR)-based surgical training system. By adjusting the stiffness of each sensor element to match that of biological tissues, the system provided real-time visual and tactile feedback according to the pressure applied during surgical incisions. It also offered real-time warnings if an incision was too deep or approached a risky area, making it a promising technology for enhancing immersion and accuracy in medical training. KAIST Professor Inkyu Park stated, “Because this sensor can be precisely tuned from the design stage and operates reliably across diverse environments, it can be used not only in everyday life, but also in a variety of fields such as healthcare, rehabilitation, and virtual reality.” The research was co-led as first authors by Dr. Jungrak Choi of ETRI, KAIST master’s student Chankyu Han, and Ph.D. candidate Donho Lee, under the overall guidance of Professor Inkyu Park. The research results were published in the May 2025 issue of ‘Science Advances’ and introduced to the global research community through the journal’s official SNS channels (Facebook, Twitter). ※ Thesis Title: Thermoforming 2D films into 3D electronics for high-performance, customizable tactile sensing ※ DOI: 10.1126/sciadv.adv0057 < Figure 3. The introduction of the study on the official SNS posting by Science Advances > This research was supported by the Ministry of Trade, Industry and Energy, the National Research Foundation of Korea, and the Korea Institute for Advancement of Technology.
2025.06.23 View 145

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