To demonstrate the wearable flexible/stretchable health-monitoring sensor, it is necessary to develop advanced functional materials and fabrication technologies. Among the various developed materials and fabrication processes for wearable sensors, carbon-based materials and textile-based configurations are considered as promising approaches due to their outstanding characteristics such as high conductivity, lightweight, high mechanical properties, wearability, and biocompatibility. Despite these advantages, in order to realize practical wearable applications, electrical and mechanical performances such as sensitivity, stability, and long-term use are still not satisfied. Accordingly, in this review, we describe recent advances in process technologies to fabricate advanced carbon-based materials and textile-based sensors, followed by their applications such as human activity and electrophysiological sensors. Furthermore, we discuss the remaining challenges for both carbon- and textile-based wearable sensors and then suggest effective strategies to realize the wearable sensors in health monitoring.

Textile-based pressure sensors have garnered considerable interest in electronic textiles due to their diverse applications, including human–machine interface and healthcare monitoring systems. We studied a textile-based capacitive pressure sensor array using a poly(vinylidene fluoride)-co-hexafluoropropylene (PVDF-HFP)/ionic liquid (IL) composite film. By constructing a capacitor structure with Ag-plated conductive fiber electrodes that are embedded in fabrics, a capacitive pressure sensor showing high sensitivity, good operation stability, and a wide sensing range could be created. By optimizing the PVDF-HFP:IL ratio (6.5:3.5), the fabricated textile pressure sensors showed sensitivity of 9.51 kPa⁻¹ and 0.69 kPa⁻¹ in the pressure ranges of 0–20 kPa and 20–100 kPa, respectively. The pressure-dependent capacitance variation in our device was explained based on the change in the contact-area formed between the multi-filament fiber electrodes and the PVDF-HFP/IL film. To demonstrate the applicability and scalability of the sensor device, a 3 × 3 pressure sensor array was fabricated. Due to its matrix-type array structure and capacitive sensing mechanism, multi-point detection was possible, and the different positions and the weights of the objects could be identified.

Flexible paper-based physiological sensor electrodes were developed using chemically-modified graphene (CG) and carboxylic-functionalized multiwalled carbon nanotube composites (f@MWCNTs). A solvothermal process with additional treatment was conducted to synthesize CG and f@MWCNTs to make CG-f@MWCNT composites. The composite was sonicated in an appropriate solvent to make a uniform suspension, and then it was drop cast on a nylon membrane in a vacuum filter. A number of batches (0%~35% f@MWCNTs) were prepared to investigate the performance of the physical characteristics. The 25% f@MWCNT-loaded composite showed the best adhesion on the paper substrate. The surface topography and chemical bonding of the proposed CG-f@MWCNT electrodes were characterized by scanning electron microscopy (SEM) and Raman spectroscopy, respectively. The average sheet resistance of the 25% CG-f@MWCNT electrode was determined to be 75 Ω/□, and it showed a skin contact impedance of 45.12 kΩ at 100 Hz. Electrocardiogram (ECG) signals were recorded from the chest and fingertips of healthy adults using the proposed electrodes. The CG-f@MWCNT electrodes demonstrated comfortability and a high sensitivity for electrocardiogram signal detection.