Stretchable Strain Gauge and Crack Detection Sensor for Harsh Environments

Authors: Bryan Cabrera, David Demoz

Field of Study: Industrial and Systems Engineering

Faculty Mentors: Mark Poliks

Easel: 31

Timeslot: Morning

Abstract: This work presents the development and characterization of low cost stretchable strain gauges and crack detection sensors for structural health monitoring of large infrastructure such as wind turbine blades. The project is a collaboration between Binghamton University and GE Vernova and addresses the lack of affordable monitoring solutions capable of detecting small defects and measuring strain across large surfaces in harsh environments. The sensors are fabricated using commercially available conductive inks and flexible substrates, enabling scalable and cost effective manufacturing. Design optimization is guided by literature on serpentine geometries and capacitive sensor architectures to improve strain transfer, sensitivity, and durability. Two sensing approaches, resistive serpentine strain gauges and parallel plate capacitive sensors, are investigated to evaluate performance under mechanical and environmental stress. Experimental fabrication using silver, carbon, and hybrid conductive inks demonstrates strong adhesion and consistent printed trace thickness, highlighting the potential of printed flexible sensors for reliable large area structural monitoring.