Continuous preparation of highly robust TPU/CNT conductive aerogel fibers with heterogeneous hierarchical structure for multifunctional applications

Extreme environments like polar regions, vast oceans, and outer space impose stringent demands on the robustness and thermal insulation of wearable smart textiles. To date, the manufacturing of smart fibers and textiles that combine these two properties is still difficult to reach. In this study, we present the design and fabrication of smart fibers capable of precise electrical response to external stimuli (e.g., strain, pressure, etc.) and with superb robustness and thermal insulation, based on a bionic heterogeneous hierarchical structure. The fibers can be manufactured continuously and rapidly, and due to the introduction of an aerogel protective layer, the fibers offer high stretchability (700 %), conductive stability (withstanding 10,000 load-unload cycles), low thermal conductivity (0.058 W m⁻¹ K⁻¹) as well as impressive resistance to abrasion and washing (withstanding up to 120 h of washing and 25,000 rubs with 1000 grit sandpaper). Furthermore, smart gloves, textile keyboard devices, and self-powered wearable sensors crafted from this fiber exhibit outstanding responsiveness. This high-performance aerogel fiber offers tremendous potential for future applications in wearable thermal management, sports and health monitoring, as well as human–machine interaction.