Low-curvature microdome-based flexible sensing platform enables precision and multimodal in-brace monitoring for adolescent idiopathic scoliosis treatment

Adolescents with moderate scoliosis require brace wear to prevent disease progression and achieve spinal correction. Traditional medical imaging for treatment efficacy evaluation necessitates multi-month assessment intervals, leaving compliance unclear and increasing risks of overcorrection, undercorrection, or skin injury. Rigid pressure sensors are limited by extra components, complex calibration, and discomfort, whereas flexible pressure sensors (soft, conformable, highly sensitive) are promising alternatives. However, there is currently a lack of research on sensor design for precise detection and depth data acquisition tailored to the biomechanical properties of braces. This study combines low-curvature microdomes with topological dispersion of carbon nanotubes (CNTs) and silver particles via a modified anodic aluminum oxide template method and dual-solvent dispersion strategy. Finite element simulations were employed to characterize the pressure distribution and deformation behavior of the low-curvature microdome structure, demonstrating its mechanical advantages over conventional geometries. After systematically investigating the dispersion states and electromechanical response of conductive filler combinations, the optimized composite (5 wt% CNTs, PDMS: Ag = 7:1) achieved a sensitivity of 55.6 kPa −1 , a detection range up to 500 kPa, and robust stability. An integrated platform was developed for capturing pressure, interfacial temperature, and respiratory signals during bracing. The platform demonstrated the feasibility of differentiating breathing patterns, characterizing Schroth breathing training, assessing pressure values at the brace-skin interface, and tracking brace compliance in real time in a preliminary single-patient evaluation. This work provides a viable strategy for high-performance flexible pressure sensor design through microstructure engineering and materials optimization, and offers an early-stage proof of concept for an integrated monitoring platform with potential utility in scoliosis brace treatment management.