Forming mechanism of flexible microneedle array based on cooperation of jet printing and magnetic field-assisted stretching for wearable triboelectric pressure sensors

Abstract Triboelectric pressure sensors with high sensitivity, broad linear range, and robust mechanical durability are critical for next-generation wearable human–machine interfaces. In this study, we present a microneedle-based triboelectric pressure sensor (MN-TPS) fabricated via a scalable additive manufacturing strategy that synergistically integrates jet printing and magnetic field-assisted stretching methods. This approach enables precise, controllable, and cost-effective fabrication of high-aspect-ratio microneedle array with tunable morphology. The optimized MN-TPS delivers an open-circuit voltage of 17.49 V under a 20 N force at 4 Hz, achieving a high-pressure sensitivity of 0.10 V/kPa at low regime (0–100 kPa) and maintaining linearity over an ultrawide range up to 400 kPa. Leveraging its fast response, we further integrate nine MN-TPS units into a wireless wearable interactive platform capable of real-time robotic control and dynamic trajectory recognition. This work bridges advanced microfabrication with practical human–machine interaction, establishing a versatile and generalizable platform for next-generation electronic skins, soft robotics, and intelligent wearable systems.