Key Takeaways & Executive Findings
- •• • Sensitivity of 0.77 kPa−1 under 30 MPa hydrostatic pressure: This high sensitivity enables detection of small gripping forces (comparable to human touch) at depths up to 3000 m, directly addressing the bottleneck of manipulating delicate specimens in deep-sea environments. • • Signal fluctuation below 1.48%: The sensor maintains stable performance under extreme pressure, ensuring reliable force feedback for precise manipulation tasks, which is critical for avoiding damage to collected samples and improving operational efficiency. • • Tunable sensitivity and detection range via lattice parameters: Adjusting the lattice structure allows customization for specific depth and force requirements, providing a versatile platform for various underwater applications, from shallow to full-ocean-depth exploration. • • Dual-curing DLP resin with micron-scale printing accuracy and seawater resistance: The material system enables rapid prototyping of complex geometries with mechanical properties comparable to thermoplastic resins, facilitating scalable manufacturing of durable deep-sea sensors.
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Abstract
The exploration and utilization of marine resources demand advanced operational tools. At present, deep-sea vehicles equipped with manipulators serve as the primary platforms for underwater exploration. However, the pressure sensors responsible for detecting the subtle gripping forces of these manipulators still face significant technical challenges, primarily due to the extreme hydrostatic pressure, corrosive seawater environment, and stringent mechanical strength requirements. A dual-curing, waterproof digital light processing (DLP) resin has been developed to achieve micron-scale printing accuracy, excellent seawater resistance, and mechanical properties comparable to those of thermoplastic resins. More importantly, the deep-sea pressure sensor (DSPS) features a unique printed lattice structure that allows seawater to penetrate and equilibrate the internal and external pressures, effectively mitigating the effects of deep-sea hydrostatic pressure. Experimental results demonstrate that the sensor exhibits a wide detection range and high sensitivity, with a measured sensitivity of 0.77 kPa−1 under 30 MPa hydrostatic pressure and a signal fluctuation below 1.48%. Furthermore, both the sensitivity and detection range of the sensor can be tuned by adjusting the lattice parameters, providing a robust foundation for the advancement of marine resource exploration.
1. Introduction
Existing deep-sea pressure sensors predominantly rely on rigid structures such as resonant quartz crystals, optical fibers, or piezoresistive elements, which necessitate protective pressure housings. These housings not only limit sensitivity but also increase size and energy consumption, hindering integration with robotic manipulators. Flexible sensors using soft materials have emerged as alternatives, offering compact designs and low production costs. However, their pressure resistance is limited, typically suitable for depths up to 1500 m, and they struggle to detect small gripping forces under extreme hydrostatic pressure due to coupling effects.
This work introduces a deep-sea pressure sensor (DSPS) fabricated via digital light processing (DLP) 3D printing using a dual-curing, waterproof polyurethane resin. The sensor features a unique lattice structure that allows seawater to penetrate and equilibrate internal and external pressures, effectively decoupling the sensing mechanism from hydrostatic pressure. This design enables high sensitivity (0.77 kPa−1) and low signal fluctuation (<1.48%) even at 30 MPa, while maintaining mechanical robustness and seawater resistance. The tunability of lattice parameters further allows optimization for specific operational depths and force ranges, providing a robust solution for deep-sea manipulation tasks.
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Jiawei Wu, Xiangling Xia, Zhiyi Gao, Zhaopeng Liu, Xiaona Feng, Hao Liu, Huihui Tian, Zidong He, Jinyun Liu, Xiaohui Yi, Baoru Bian, Jie Shang, Huayang Li, Run-Wei Li (2025). A deep-sea pressure sensor capable of sensing small gripping forces without coupling. SCIENCE CHINA Materials. https://doi.org/10.1007/s40843-025-3732-2
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Frequently Asked Questions
What is the maximum hydrostatic pressure the sensor can withstand, and how does it maintain performance?
The sensor operates reliably at 30 MPa hydrostatic pressure (equivalent to ~3000 m depth) with a sensitivity of 0.77 kPa−1 and signal fluctuation below 1.48%. The lattice structure allows seawater to penetrate, equilibrating internal and external pressures, thus mitigating the effects of hydrostatic pressure on the sensing element.
How does the sensor address the coupling between hydrostatic pressure and gripping force detection?
The printed lattice structure enables pressure equilibration, decoupling the sensing mechanism from hydrostatic pressure. This allows the sensor to detect small gripping forces without interference from the ambient pressure, as evidenced by stable performance under 30 MPa.
What are the mechanical properties of the dual-curing DLP resin, and how do they compare to thermoplastic resins?
The dual-curing DLP resin achieves micron-scale printing accuracy and mechanical properties comparable to thermoplastic resins, including high strength and seawater resistance. This ensures durability and reliability in corrosive deep-sea environments.
Can the sensor's sensitivity and detection range be customized for different depths?
Yes, both sensitivity and detection range can be tuned by adjusting the lattice parameters. This tunability allows optimization for specific operational depths and force requirements, providing flexibility for various deep-sea missions.
What is the signal fluctuation under extreme pressure, and why is this important?
The signal fluctuation is below 1.48% under 30 MPa, ensuring reliable and accurate force feedback. This low fluctuation is critical for precise manipulation tasks, preventing damage to delicate samples and improving operational efficiency.
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