A groundbreaking advancement in wearable technology has come from a research team led by Si Cheng at Soochow University, who have recently provided a comprehensive review of electrospun nanofiber-based composite materials designed for next-generation wearable electronic skin (E-skin) applications. Published in the esteemed journal Nano-Micro Letters, this work consolidates recent progress in electrospinning techniques and composite design strategies, revealing the immense potential of these materials to revolutionize human physical, physiological, and body fluid signal monitoring. The convergence of materials science and bioengineering embodied in these studies heralds a new era of highly sensitive, flexible, and multifunctional wearable sensors.
Electrospinning, a versatile and scalable technology for producing ultrafine polymer fibers, stands at the core of this innovation. The process generates nanofibers possessing high surface area-to-volume ratios, exceptional porosity, and remarkable mechanical flexibility, all of which are essential attributes for wearable electronics mimicking human skin. By fine-tuning the electrospinning parameters, researchers can tailor fiber morphologies—from solid to porous or even hollow structures—optimizing them for specific sensing functions. The technology also facilitates the fabrication of hybrid composites where these nanofibers are integrated with hydrogels, aerogels, or metallic elements, thereby enhancing electrical conductivity, biocompatibility, and mechanical robustness.
The review situates electrospun nanofiber composites as a versatile platform, emphasizing the importance of material hybridization and architectural control. One of the pivotal aspects highlighted is the synergy between nanofibers and hydrogels. Hydrogels offer exceptional biocompatibility and conformability to complex skin contours, attributes indispensable for continuous physiological monitoring. However, their Achilles’ heel—namely, water loss leading to mechanical and sensing instability—necessitates composite integration with nanofibers to reinforce these features and extend operational durability, marking a significant stride toward real-world application.
Aerogel composites featuring electrospun nanofibers bring another dimension to wearable sensors by combining lightweight, porous frameworks with superior mechanical resilience. The nanofibers act as reinforcements within the aerogel matrix, mitigating brittleness and facilitating flexibility while maintaining breathability. These properties enable sensors to endure repeated deformations without compromising sensitivity, a requirement critical for strain and pressure monitors applied to the human body.
The inclusion of metallic components within nanofiber-based composites has propelled the field further by imparting precise electrical conductivity and enabling micro- or nanoscale circuit patterning essential for signal transduction. Nevertheless, integrating traditionally rigid metals with flexible polymer nanofibers demands ingenious approaches to preserve flexibility without sacrificing electrical performance. The reviewed works detail innovative fabrication methods and functionalization strategies, such as coating or in situ polymerization, which seamlessly meld these disparate materials, overcoming longstanding material incompatibility challenges.
In terms of signal types, the reviewed composites excel across a diverse spectrum. Physical parameter monitoring benefits from the intrinsic elasticity and conformability of the composites, allowing detection of strain, pressure, temperature, and even acoustic vibrations with high fidelity. This versatility stems from the tunable porosity and fiber alignment achieved through electrospinning, which modulates mechanical responses while preserving user comfort and sensor responsiveness.
Physiological signals, including electrocardiograms (ECG), electromyograms (EMG), electroencephalograms (EEG), and electrooculograms (EOG), require electrodes with low impedance and elevated signal-to-noise ratios to ensure accurate measurements. Electrospun nanofiber composites have demonstrated superior performance in these domains, notably surpassing conventional silver/silver chloride (Ag/AgCl) electrodes, especially under dynamic conditions typical of wearable environments. This improvement is attributed to enhanced skin-electrode contact, reduced motion artifacts, and inherent flexibility.
Monitoring biochemical markers in body fluids represents a frontier application for these composites. Sweat, saliva, urine, and blood analyses for metabolites like glucose, lactate, and cortisol are increasingly feasible through nanofiber-based sensors, which offer high sensitivity and selectivity. The porous morphology and multifunctionality enable integration of enzymatic or electrochemical sensing elements while maintaining user comfort and sensor durability, crucial for continuous personalized healthcare diagnostics and disease management.
An emerging trend underscored throughout the review is multimodal sensing, wherein single devices simultaneously capture multiple parameters without cross-interference. This feat is accomplished via spatial or temporal signal decoupling facilitated by specific nanofiber composite designs, sensor architecture, and advanced signal processing algorithms. Such capability paves the way for holistic monitoring platforms capturing comprehensive health and environmental data in real time.
Despite these advances, challenges remain. Achieving an optimal balance between sensitivity and dynamic range continues to test materials engineers, as does minimizing power consumption for long-term, continuous monitoring. Mechanical stability over extended use periods and ensuring biocompatibility to prevent skin irritation further complicate device development. Addressing these issues will require integrated efforts spanning materials innovation, device engineering, and interface design.
The research landscape is also heading toward sustainable and self-healing materials. Development of recyclable nanofiber composites and incorporation of self-repair mechanisms promise greater device longevity and reduced environmental impact, aligning wearable electronics with circular economy principles. Moreover, integrating these composites with wireless communication modules and artificial intelligence-driven data analytics is shaping a future where real-time, intelligent interpretation of complex physiological data becomes standard in personalized healthcare.
This comprehensive review elucidates how electrospun nanofiber-based composites stand as a transformative platform uniting material science ingenuity with biomedical engineering aspirations. Their skin-like mechanical properties and multifunctionality lay the foundation for the next generation of electronic skins capable of seamless human-machine interaction, healthcare monitoring, and intelligent robotics. As nanofiber design and multifunctional sensing technologies mature, the realization of flexible, high-performance E-skin systems within everyday use seems imminent.
In sum, the research led by Si Cheng and collaborators crystallizes the evolving role of electrospun nanofiber composites in wearable sensor technology. The review elegantly maps out progress from fundamental material design to sophisticated multifunctional applications, underscoring emergent trends and persisting challenges. This work acts as both a testament to past innovation and a clarion call for future interdisciplinary exploration—one that promises to redefine how humans interact with technology and monitor health in an increasingly connected world.
Stay tuned to the ongoing transformative developments in this dynamic field, as researchers worldwide continue advancing nanofiber composite materials and multifunctional sensing strategies. Their breakthroughs not only push the boundaries of wearable electronics but also edge us closer to a future where personalized, real-time health monitoring is seamlessly integrated into daily life, empowering individuals and healthcare providers alike.
Subject of Research: Electrospun Nanofiber-Based Composite Materials for Wearable Electronic Skin Applications
Article Title: Recent Progress of Electrospun Nanofiber-Based Composite Materials for Monitoring Physical, Physiological, and Body Fluid Signals
News Publication Date: 18-Jun-2025
Web References: 10.1007/s40820-025-01804-2
Image Credits: Fang Guo, Zheng Ren, Shanchi Wang, Yu Xie, Jialin Pan, Jianying Huang, Tianxue Zhu, Si Cheng, Yuekun Lai
Keywords: Nanofibers, Electrospinning, Composite Materials, Wearable Sensors, Electronic Skin, Physiological Signal Monitoring, Body Fluid Analysis
