Vibration sensors are integral to a multitude of engineering applications, yet the development of low-cost, easily assembled devices remains a formidable challenge. This study presents a highly sensitive flexible vibration sensor, based on the piezoresistive effect, tailored for the detection of high-dynamic-range vibrations and accelerations. The sensor’s design incorporates a polylactic acid (PLA) housing with cavities and spherical recesses, a polydimethylsiloxane (PDMS) membrane, and electrodes that are positioned above. Employing femtosecond laser ablation and template transfer techniques, a parallel groove array is created within the flexible polymer sensing layer. This includes conductive pathways, and integrates stainless-steel balls as oscillators to further amplify the sensor’s sensitivity. The sensor’s performance is evaluated over a frequency range of 50 Hz to 400 Hz for vibrations and from 1 g to 5 g for accelerations, exhibiting a linear correlation coefficient of 0.92 between the sensor’s voltage output and acceleration. It demonstrates stable and accurate responses to vibration signals from devices such as drills and mobile phone ringtones, as well as robust responsiveness to omnidirectional and long-distance vibrations. The sensor’s simplicity in microstructure fabrication, ease of assembly, and low cost render it highly promising for applications in engineering machinery with rotating or vibrating components.

Flexible sensors have emerged as essential components in next-generation technologies such as wearable electronics, smart healthcare, soft robotics, and human–machine interfaces, owing to their outstanding mechanical flexibility and multifunctional sensing capabilities. Despite significant advancements, challenges such as the trade-off between sensitivity and detection range, and poor signal stability under cyclic deformation remain unresolved. To overcome the aforementioned limitations, this work introduces a high-performance soft sensor featuring a dual-layered electrode system, comprising silver nanoparticles (AgNPs) and a composite of multi-walled carbon nanotubes (MWCNTs) with carbon black (CB), coupled with a laser-engraved crack-gradient microstructure. This structural strategy facilitates progressive crack formation under applied strain, thereby achieving enhanced sensitivity (1.56 kPa⁻¹), broad operational bandwidth (50–600 Hz), fine frequency resolution (0.5 Hz), and a rapid signal response. The synergistic structure also improves signal repeatability, durability, and noise immunity. The sensor demonstrates strong applicability in health monitoring, motion tracking, and intelligent interfaces, offering a promising pathway for reliable, multifunctional sensing in wearable health monitoring, motion tracking, and soft robotic systems.