Robust and highly-sensitive wearable human-machine interfaces enabled by mechanically interlocked LIG textiles via thermal lamination

Laser-induced graphene (LIG) provides a direct and scalable route to fabricate smart textiles with pressure-sensing capabilities, yet it often faces a trade-off between robust durability and high sensitivity due to the inherent fragility of laser-scribed structures. Here, we report a thermal-lamination strategy that creates a mechanical-interlocked interface between a thermoplastic polyurethane (TPU) film and a LIG layer patterned on aramid fabrics, enabling concurrent improvements in mechanical robustness and pressure sensitivity. Specifically, by first tailoring the LIG microstructure via laser-parameter optimization (2.5 W, 5 mm defocus) and subsequently integrating a TPU layer under optimized thermal conditions (150 °C, 0 MPa), the pressure sensitivity of the LIG sensor increases dramatically from 0.12 kPa⁻¹ to 1.48 kPa⁻¹, while simultaneously delivering a rapid response (<20 ms), a broad detection range (10 Pa–160 kPa), and excellent stability over 5000 cycles. Finally, we demonstrate a multifunctional smart textile wristband capable of continuous physiological monitoring, high-accuracy gesture recognition, and wrist-activity tracking, validating its potential for next generation wearable electronics and human-machine interfaces.