The development of a flexible surface acoustic wave (SAW) sensor as microelectromechanical systems (MEMS) device has been gradually emerged due to its unobtrusive size, passive, and wireless competencies. The concept behind this work is to additively develop a flexible surface acoustic wave (SAW) device with enhanced electromechanical properties capable of detecting mechanical strain occurring in aerospace applications. The nanocomposite substrate is made of polyvinylidene fluoride (PVDF) owing to its flexibility, piezoelectricity, long-term stability, and easy processing incorporated with carbon nanotubes (CNTs) as nanofillers. Adding CNTs to the polymer matrix for electromechanical properties enhancement is investigated through additive manufacturing (AM) process. Both the thin substrate and the interdigital transducer (IDT) are fabricated through direct digital manufacturing (DDM), exhibiting favorable piezoelectric and electrical properties. Various device characteristics of fabricated SAW sensor, including the generation and propagation of Rayleigh waves and the changes in wave characteristics, such as frequency, admittance, and impedance, are discussed in this paper. The effects of IDT dimensions and the resonant frequency response of the developed SAW device are also examined with numerical analysis.
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