3D-Printed Gyroid Architecture for Pressure Sensor Applications

The gyroid structure represents a design renowned for its high strength and exceptional energy-absorbing qualities, rendering it a suitable choice for deployment as an energy damping device. Within the family of related gyroid structures, we have opted for the Slab single gyroid (Slab SG) model. This model has been meticulously crafted using the 3D printing method, with the intention of utilizing it as the basis for a capacitance-based pressure sensor. In this work, we introduce a simulation model to homogenize the variations introduced by the FDM manufacturing process. Our results indicate that the profile of the fused layer model, with a Young's modulus of 48.7%, exhibits performance closest to the isotropic model. To delve into the energy buffering capabilities of the Slab SG structure, we have developed a suite of closely related gyroid structures. Based on the model that demonstrates the highest linearity, we have fabricated a gyroid-based sensor. This sensor features an electrode network crafted with conductive ink via robot-assisted 3D printing. These electrodes are thoughtfully integrated into the parallel curved surface of the Slab SG structure to maximize the capacitance formed and, subsequently, the sensitivity of the sensor. We have devised a reinforced gyroid-based liner to ensure a uniform force distribution, thereby facilitating the assembly of components for an application in smart helmets.