Embedded Sensors with 3D Printing Technology: Review

Embedded Sensors with 3D Printing Technology: Review

19 March 2024 | Joan Bas, Taposhree Dutta, Ignacio Llamas Garro, Jesús Salvador Velázquez-González, Rakesh Dubey and Satyendra K. Mishra
This review discusses embedded sensors with 3D printing technology, focusing on their development, integration into structures, and applications. Embedded sensors (ESs) are used in smart materials to enable continuous and permanent measurements of structural integrity. The integration of ESs has been limited by the processing technology used to implant the sensor, but 3D-printed sensors are gaining popularity due to improved assembly processes, reduced system complexity, and lower fabrication costs. Two methods can be used to integrate sensors: attaching them to surfaces or embedding them in structures. Various additive manufacturing techniques, such as fused filament fabrication (FFF), stereolithography (SLA), direct ink writing (DIW), and laser powder bed fusion (LPBF), are used to fabricate embedded sensors. These techniques allow for the creation of complex geometries and the integration of multiple materials. The review discusses different types of embedded sensors, their sensing mechanisms, and applications in various fields such as medicine, space, industry, agriculture, and automobiles. Fiber optic sensors (FOSs) and piezoelectric sensors (PSs) are commonly used to develop embedded sensors. FOSs are durable and can withstand high tensile stresses and corrosion, while PSs are used for structural health monitoring (SHM) systems. The review also discusses the challenges and future prospects of embedded sensors using 3D printing, including issues such as sensor damage, signal-to-noise ratio, and the need for accurate embedding. The review highlights the advantages of 3D printing in creating embedded sensors, including the ability to produce complex geometries, integrate multiple materials, and reduce fabrication costs. It also discusses the potential of 3D printing in creating wireless sensors, which can detect pressure, temperature, motion, and other physical and environmental characteristics. The review concludes that 3D printing offers a promising approach for the development of embedded sensors with improved functionality and performance.This review discusses embedded sensors with 3D printing technology, focusing on their development, integration into structures, and applications. Embedded sensors (ESs) are used in smart materials to enable continuous and permanent measurements of structural integrity. The integration of ESs has been limited by the processing technology used to implant the sensor, but 3D-printed sensors are gaining popularity due to improved assembly processes, reduced system complexity, and lower fabrication costs. Two methods can be used to integrate sensors: attaching them to surfaces or embedding them in structures. Various additive manufacturing techniques, such as fused filament fabrication (FFF), stereolithography (SLA), direct ink writing (DIW), and laser powder bed fusion (LPBF), are used to fabricate embedded sensors. These techniques allow for the creation of complex geometries and the integration of multiple materials. The review discusses different types of embedded sensors, their sensing mechanisms, and applications in various fields such as medicine, space, industry, agriculture, and automobiles. Fiber optic sensors (FOSs) and piezoelectric sensors (PSs) are commonly used to develop embedded sensors. FOSs are durable and can withstand high tensile stresses and corrosion, while PSs are used for structural health monitoring (SHM) systems. The review also discusses the challenges and future prospects of embedded sensors using 3D printing, including issues such as sensor damage, signal-to-noise ratio, and the need for accurate embedding. The review highlights the advantages of 3D printing in creating embedded sensors, including the ability to produce complex geometries, integrate multiple materials, and reduce fabrication costs. It also discusses the potential of 3D printing in creating wireless sensors, which can detect pressure, temperature, motion, and other physical and environmental characteristics. The review concludes that 3D printing offers a promising approach for the development of embedded sensors with improved functionality and performance.
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