Plasma-induced microcracked stretchable strain sensor array for multifunctional wireless sensing in smart tires

Owing to ultra-high sensitivity, microcrack-based flexible strain sensors have emerged as critical enablers for next-generation soft perception. However, the intrinsic structural instability of microcrack networks leads to severe signal drift and decay under long-term cyclic impact, posing a critical barrier to their practical deployment. Here, we present an ultra-durable, rubber-integrated sensor array based on a plasma-induced crack strain (PICS) strategy, enabling distributed force analysis and real-time road perception for smart tires. By leveraging tangential stress generated by a plasma-oxidized hardened surface, through-type cracks are induced in the multi-walled carbon nanotube (MWCNT) network. Simultaneously, CNTs are embedded and anchored within the hardened matrix, enhancing interfacial adhesion and preventing delamination during prolonged, high-strain deformation. The sensors endure continuous 200,000 cycles at 100% strain with negligible hysteresis, achieve a 0.005% detection limit and gauge factors up to 1355 (60–100%). Road tests over 70 km and 20,000 high-frequency impacts confirm stable performance. A 21-sensor array embedded in the inner tire surface enables the detection of acceleration, load, and road pavement, offering a scalable route to intelligent tires with real-time mechanical awareness for autonomous driving and enhanced safety. © 2026 Elsevier B.V.