--- title: "3D-Printed Sensors: Emerging Strategies and Materials" id: "9418" type: "post" slug: "3d-printed-sensors-emerging-strategies-and-materials" published_at: "2025-08-11T18:23:56+00:00" modified_at: "2026-04-20T18:57:53+00:00" url: "https://www.plasticsengineering.org/2025/08/3d-printed-sensors-emerging-strategies-and-materials-009418/" markdown_url: "https://www.plasticsengineering.org/2025/08/3d-printed-sensors-emerging-strategies-and-materials-009418.md" excerpt: "Additive manufacturing, or 3D printing, pushes conventional limits for manufacturing sensors used for monitoring environmental changes and conditions." taxonomy_category: - "3D Printing/Additive Manufacturing" - "Building & Construction" - "Composites" - "Equipment" - "Industry" - "Materials" - "Medical" - "Process" - "Sensors" - "Trending" taxonomy_post_tag: - "3D Printing" - "biomedical applications" - "carbon nanotubes" - "carbon-based inks" - "gas sensors" - "soft pressure sensor" - "stratasys" - "TangoPlus™ FLX930" --- [Home](https://www.plasticsengineering.org/) » [News](https://www.plasticsengineering.org/news/) » [Trending](https://www.plasticsengineering.org/c/trending/) » [Equipment](https://www.plasticsengineering.org/c/trending/equipment/) » [Sensors](https://www.plasticsengineering.org/c/trending/equipment/sensors/) » 3D-Printed Sensors: Emerging Strategies and Materials # 3D-Printed Sensors: Emerging Strategies and Materials Manufacturers can apply 3D printing's benefits to sensor fabrication, creating complex designs with minimal resources.### Additive manufacturing, or 3D printing, pushes conventional limits for manufacturing sensors used for monitoring environmental changes and conditions. Because 3D printing enables the fabrication of complex geometries, it is gaining popularity for sensor manufacturing. Benefits such as allowing fabrication directly on complex, nonplanar structures make [3D printing a viable alternative](https://link.springer.com/article/10.1007/s40684-024-00629-5#Tab1) for conventional manufacturing. Additionally, 3D printing can reduce cost and processing time while increasing design flexibility. **You can also read:** [Polymeric Biosensors: A New Era in Medical Diagnostics.](https://www.plasticsengineering.org/2024/05/polymeric-biosensors-a-new-era-in-medical-diagnostics-004832/) Manufacturers can embed sensor components in 3D-printed housing or, in some applications, print the entire sensor at once. Since sensors comprise various materials, they require 3D printing systems that can fabricate using multiple materials simultaneously. Few systems are currently capable of this; thus, a hybrid approach is often employed, combining various manufacturing methods. Hybrid manufacturing combines 3D-printed components with separately manufactured components. Courtesy of [Additive Manufacturing of Sensors: A Comprehensive Review.](https://link.springer.com/article/10.1007/s40684-024-00629-5) Another key advantage of 3D printing is resource optimization, which can emphasize sustainability. Manufacturers can lower their carbon footprint with less wasted material and more precise designs. Filaments created from waste materials can also allow for manufacturing sensors from recycled materials. ## What Materials are Usable for 3D-Printed Sensors? For fully 3D-printed sensors, carbon-based inks or carbon nanotubes (CNT) are essential for printing soft sensors. For example, to fabricate a soft pressure sensor, researchers employed the photopolymer [TangoPlus™ FLX930](https://www.stratasys.com/en/materials/materials-catalog/polyjet-materials/tango/) (Stratasys) as an insulating layer. Researchers then covered the layer with CNT electrodes, then covered the electrodes with an ionic layer (1-ethyl-3-methyl-imidazolium tetrafluoroborate). Positioning the sensor between two electrodes establishes sensitive units at the intersections. Researchers created this soft, flexible, three-material sensor using a 3D printer with three extrusion heads. Courtesy of [Additive Manufacturing of Sensors: A Comprehensive Review.](https://link.springer.com/article/10.1007/s40684-024-00629-5) Various polymers are suitable for 3D printing; manufacturers should select a polymer based on the desired application. For example, gas sensors can detect ammonia using polylactic acid (PLA) combined with copper particles. The more common hybrid 3D-printed sensors allow for plenty of material variety. Silicon rubber is useful for both industrial pressure sensors and, in biomedical applications, certain artificial organs. Arsenic detectors are an example of an electrochemical sensor that uses nanocomposites. Hydrogel is diversely applicable for 3D-printed sensing layers. Polyvinylidene fluoride (PVDF) has application potential for 3D printed piezoelectric devices due to its vibration detection capabilities. **You can also read:** [Polymeric Biosensors: A New Era in Medical Diagnostics.](https://www.plasticsengineering.org/2024/05/polymeric-biosensors-a-new-era-in-medical-diagnostics-004832/) ## Avenues for Future Research 3D printing is an exciting avenue for sensor manufacturing. Still, technological limitations pose challenges for researchers and manufacturers in this space. As aforementioned, the lack of multi-material systems prevents fully 3D-printed sensors from becoming more ubiquitous. Along the same line, not all materials are printable. Without access to the proper material, sensors may have limited performance. Additionally, 3D-printed sensors still require connection with electronic devices, and wires are not always compatible with sensor materials. Hybrid-manufactured sensors are already commercially available. As research continues, fully 3D-printed sensors may become more feasible. This can allow manufacturers to better seize the benefits of 3D printing. By **[Julienne Smith](https://www.plasticsengineering.org/author/juliennesmith/)** | August 11, 2025 ##### [Julienne Smith](https://www.plasticsengineering.org/author/juliennesmith/) [+ postsBio ⮌](#) - Julienne Smith [Upcycling Polyolefins into Jet Fuel Components](https://www.plasticsengineering.org/2026/04/upcycling-polyolefins-into-jet-fuel-components-011138/) - Julienne Smith [Renewable Functional Coatings for Advanced Applications](https://www.plasticsengineering.org/2026/04/renewable-functional-coatings-for-advanced-applications-011134/) - Julienne Smith [Nanocomposite Films from Car Bumper Waste](https://www.plasticsengineering.org/2026/04/nanocomposite-films-from-car-bumper-waste-011041/) - Julienne Smith [Emerging Markets for Polyolefins in the Solar Industry](https://www.plasticsengineering.org/2026/04/emerging-markets-for-polyolefins-in-the-solar-industry-011128/) ### Other posts you could read [April 28, 2026IKV Colloquium 2026: The Journey of Research and Industry](https://www.plasticsengineering.org/2026/04/ikv-colloquium-2026-the-journey-of-research-and-industry-010989/) [May 4, 2026Why Your Feeder Choice Is Quietly Undermining Consistency](https://www.plasticsengineering.org/2026/05/why-your-feeder-choice-is-quietly-undermining-consistency-011175/) [May 13, 2026The Logistics Challenge of Scaling Mechanical Recycling](https://www.plasticsengineering.org/2026/05/the-logistics-challenge-of-scaling-mechanical-recycling-011251/) [April 23, 2026Conductive Polymers Revolutionize Fuel Cell Plates](https://www.plasticsengineering.org/2026/04/conductive-polymers-revolutionize-fuel-cell-plates-011057/) [May 7, 2026PCR Plastics Are Redefining Aesthetic Standards](https://www.plasticsengineering.org/2026/05/pcr-plastics-are-redefining-aesthetic-standards-011186/) [April 30, 2026Upcycling Polyolefins into Jet Fuel Components](https://www.plasticsengineering.org/2026/04/upcycling-polyolefins-into-jet-fuel-components-011138/) [April 22, 2026Beyond Flaps: How Composite Skins Enable Morphing Wing Design](https://www.plasticsengineering.org/2026/04/beyond-flaps-how-composite-skins-enable-morphing-wing-design-010950/) [April 17, 2026Conveying PCR: Reducing Fines, Angel Hair, and Scrap](https://www.plasticsengineering.org/2026/04/conveying-pcr-reducing-fines-angel-hair-and-scrap-011052/) ## Share Your Thoughts [Cancel reply](/2025/08/3d-printed-sensors-emerging-strategies-and-materials-009418/#respond) - [https://twitter.com/share?url=https://www.plasticsengineering.org/?p=9418&text=3D-Printed+Sensors%3A+Emerging+Strategies+and+Materials&via=Plastics_Mag](https://twitter.com/share?url=https://www.plasticsengineering.org/?p=9418&text=3D-Printed+Sensors%3A+Emerging+Strategies+and+Materials&via=Plastics_Mag) - [https://www.facebook.com/sharer.php?u=https://www.plasticsengineering.org/?p=9418&t=3D-Printed+Sensors%3A+Emerging+Strategies+and+Materials](https://www.facebook.com/sharer.php?u=https://www.plasticsengineering.org/?p=9418&t=3D-Printed+Sensors%3A+Emerging+Strategies+and+Materials) - [https://www.linkedin.com/shareArticle?mini=true&url=https://www.plasticsengineering.org/?p=9418&title=3D-Printed%20Sensors:%20Emerging%20Strategies%20and%20Materials&summary=Additive+manufacturing%2C+or+3D+printing%2C+pushes+conventional+limits+for+manufacturing+sensors+used+for+monitoring+environmental+changes+and+conditions.&source=Plastics+Engineering](https://www.linkedin.com/shareArticle?mini=true&url=https://www.plasticsengineering.org/?p=9418&title=3D-Printed%20Sensors:%20Emerging%20Strategies%20and%20Materials&summary=Additive+manufacturing%2C+or+3D+printing%2C+pushes+conventional+limits+for+manufacturing+sensors+used+for+monitoring+environmental+changes+and+conditions.&source=Plastics+Engineering) - [https://www.reddit.com/submit?url=https://www.plasticsengineering.org/?p=9418&title=3D-Printed+Sensors%3A+Emerging+Strategies+and+Materials](https://www.reddit.com/submit?url=https://www.plasticsengineering.org/?p=9418&title=3D-Printed+Sensors%3A+Emerging+Strategies+and+Materials) - [/cdn-cgi/l/email-protection#93ace0e6f1f9f6f0e7aec3fff2e0e7faf0e0b3d6fdf4fafdf6f6e1fafdf4b3beb3a0d7bec3e1fafde7f6f7b3c0f6fde0fce1e0a9b3d6fef6e1f4fafdf4b3c0e7e1f2e7f6f4faf6e0b3f2fdf7b3def2e7f6e1faf2ffe0b5f1fcf7eaaefbe7e7e3e0a9bcbce4e4e4bde3fff2e0e7faf0e0f6fdf4fafdf6f6e1fafdf4bdfce1f4bcace3aeaaa7a2ab](/cdn-cgi/l/email-protection#93ace0e6f1f9f6f0e7aec3fff2e0e7faf0e0b3d6fdf4fafdf6f6e1fafdf4b3beb3a0d7bec3e1fafde7f6f7b3c0f6fde0fce1e0a9b3d6fef6e1f4fafdf4b3c0e7e1f2e7f6f4faf6e0b3f2fdf7b3def2e7f6e1faf2ffe0b5f1fcf7eaaefbe7e7e3e0a9bcbce4e4e4bde3fff2e0e7faf0e0f6fdf4fafdf6f6e1fafdf4bdfce1f4bcace3aeaaa7a2ab) - [#comments](#comments)