Preload-Free Conformal Integration of Tactile Sensors on the Fingertip’s Curved Surface

Humans could sensitively perceive and identify objects through dense mechanoreceptors distributed on the skin of curved fingertips. Inspired by this biological structure, this study presents a general conformal integration method for flexible tactile sensors on curved fingertip surfaces. By adopting a spherical partition design and an inverse mode auxiliary layering process, it ensures the uniform distribution of stress at different curvatures. The sensor adopts a 3 × 3 tactile array configuration, replicating the 3D curved surface distribution of human mechanoreceptors. By analyzing multi-point outputs, the sensor reconstructs contact pressure gradients and infers the softness or stiffness of touched objects, thereby realizing both structural and functional bionics. These sensors exhibit excellent linearity within 0–100 kPa (sensitivity ≈ 36.86 kPa−1), fast response (2 ms), and outstanding durability (signal decay of only 1.94% after 30,000 cycles). It is worth noting that this conformal tactile fingertip integration method not only exhibits uniform responses at each unit, but also has the preload-free advantage, and then performs well in pulse detection and hardness discrimination. This work provides a novel bioinspired pathway for conformal integration of tactile sensors, enabling artificial skins and robotic fingertips with human-like tactile perception.