Numerical Simulation-Based Design of Conductive Polymer Composites

This work presents a simulation-driven approach for designing patterned flexible sensors based on laser-induced porous carbon composites. By implementing a large-deformation electromechanical coupling model into ABAQUS via a user subroutine, we efficiently predicted strain-dependent conductivity. High-throughput simulations were conducted to evaluate serpentine structures with varying geometric parameters. Key performance indicators—linearity, sensitivity, and directional selectivity—were assessed, and Pareto-optimal solutions were identified to enable multi-objective optimization. Compared to experimental trials, this method reduces design time by over 90%. The proposed framework offers a rapid and generalizable strategy for optimizing high-performance flexible sensors with anisotropic electromechanical properties.