3D printing of multiaxial force sensors using carbon nanotube (CNT)/thermoplastic polyurethane (TPU) filaments

•FDM 3D printing of carbon nanotube/thermoplastic polyurethane nanocomposite.•Monolithic manufacturing process of multiaxial force sensors (Fx, Fy, and Fz).•3D cross cubic structure is proposed for multiaxial force sensing.•High sensitivity to small forces by using a piezoresistivity. We developed a new method to directly fabricate 3D multiaxial force sensor using fused deposition modeling (FDM) 3D printing of functionalized nanocomposite filaments. Here, 3D cubic cross shaped force sensor is suggested to measure the forces from three axes (x, y and z). The sensor has two components – a structural part and a sensing part – both of which are concurrently fabricated by 3D printing with different functional filaments. The structural part is printed with thermoplastic polyurethane (TPU) filament and the sensing part is printed with carbon nanotube (CNT)/TPU nanocomposite filament with a piezoresistivity on the surface of the structural part. The resistances of the sensing part are measured in three axial directions; Rx, Ry, and Rz and the force applied on each axis is measured by the resistance change. The 3D-printed multiaxial force sensor could detect the sub-millimeter scale deflection and its corresponding force on each axis. According to the sensing principle, when Fz=4N was applied, Rz was decreased by 2% while only 0.2% resistance change of Ry was induced. In addition, a simultaneous resistance measurement system was developed for a real-time force sensing in three axes. With its customizability, rapid manufacturing, and economic feasibility, this manufacturing approach allows direct fabrication of multiaxial sensors without additional assembly or integration processes.