Structural health monitoring (SHM) has been increasingly investigated for decades. Different physical principles have been developed for damage identification, such as electronics, mechanics, magnetics, etc., with different coverage (i.e., global, large‐area, and local monitoring) and sensitivity. Mechanical acousto‐ultrasonic‐based methods have formed a big family in SHM technologies. Multiple wave/resonance modes have been utilized for versatile SHM tasks. The permanently integrated sensing networks play a significant role in achieving a cost‐effective and reliable SHM system, with major concerns including weight increase for large‐scale deployment and conformity for complex geometry structures. In this review, typical acousto‐ultrasonic sensors made of different material systems are discussed, along with advantages and limitations. Moreover, advanced network installation methods have been introduced, including surface‐mounting with pre‐integrated networks on substrates and in situ printing, and embedding with composite layup and metal additive manufacturing. Sensor versatility and usage in multi‐scale SHM techniques are then highlighted. Different wave/resonance modes are transmitted and received with corresponding elements and network designs. In conclusion, this systematic review mainly covers a collection of acousto‐ultrasonic sensors, two modalities of network installation, and their employment with various SHM methods, hopefully providing a useful guide to building lightweight and conformal networks with passive or active‐passive sensors, and developing complete and reliable SHM strategies by integrating different damage identification methods on multiple scales.

A new breed of nanocomposite-based spray-on sensor is developed for in-situ active structural health monitoring (SHM). The novel nanocomposite sensor is rigorously designed with graphene as the nanofiller and polyvinylpyrrolidone (PVP) as the matrix, fabricated using a simple spray deposition process. Electrical analysis, as well as morphological characterization of the spray-on sensor, was conducted to investigate percolation characteristic, in which the optimal threshold (~0.91%) of the graphene/PVP sensor was determined. Owing to the uniform and stable conductive network formed by well-dispersed graphene nanosheets in the PVP matrix, the tailor-made spray-on sensor exhibited excellent piezoresistive performance. By virtue of the tunneling effect of the conductive network, the sensor was proven to be capable of perceiving signals of guided ultrasonic waves (GUWs) with ultrahigh frequency up to 500 kHz. Lightweight and flexible, the spray-on nanocomposite sensor demonstrated superior sensitivity, high fidelity, and high signal-to-noise ratio under dynamic strain with ultralow magnitude (of the order of micro-strain) that is comparable with commercial lead zirconate titanate (PZT) wafers. The sensors were further networked to perform damage characterization, and the results indicate significant application potential of the spray-on nanocomposite-based sensor for in-situ active GUW-based SHM.