Preparation and Performance Analysis of 3D Thermoformed Fluidic Polymer Temperature Sensors for Aquatic and Terrestrial Applications

Employing a combination of Polyethylene terephthalate (PET) thermoforming and 3D-printed cylindrical patterns, we carefully engineer a linear resistive temperature sensor. This intricate process involves initial PET thermoforming, yielding a hollow cylindrical chamber. This chamber is then precisely infused with a composite fluid of graphite and water glue. Ensuring electrical connectivity, both ends are affixed with metal wires and securely sealed using a hot gun. This cost-effective, versatile sensor adeptly gauges temperature shifts by assessing composite fluid resistance alterations. Its PET outer surface grants immunity to water and solubility concerns, enabling application in aquatic and aerial settings without extra encapsulation. Rigorous testing reveals the sensor’s linearity and stability within a 10 °C to 60 °C range, whether submerged or airborne. Beyond 65 °C, plastic deformation arises. To mitigate hysteresis, a 58 °C operational limit is recommended. Examining fluidic composite width and length effects, we ascertain a 12 Ω/°C sensitivity for these linear sensors, a hallmark of their precision. Impressive response and recovery times of 4 and 8 s, respectively, highlight their efficiency. These findings endorse thermoforming’s potential for fabricating advanced temperature sensors. This cost-effective approach’s adaptability underscores its viability for diverse applications.