Wearable devices developed with flexible electronics have great potential applications for human health monitoring and motion sensing. Although material softness and structural flexibility provide a deformable human–machine interface to adapt to joint bending or tissue stretching/compression, flexible sensors are inconvenient in practical uses as they usually require calibration every time they are installed. This article presents an approach to design and fabricate a flexible curvature sensor to measure human articular movements for amphibious applications. This flexible sensor employs the capacitive sensing principle, where the dielectric layer and electrodes are made from the polyurethane resin and eutectic gallium-indium (EGaIn) liquid metal; and the fabrication process is implemented with shape deposition molding for batch production. The sensing method for articular rotation angles employs the Euler beam model to make the sensor reusable after one-time calibration by compensating for the unpredicted manual installation error. The illustrative application to ankle sensing in amphibious gaits shows that the root-mean-square error is within 5° for different walking speeds (0.7–1.1 m/s) in treadmill tests and the maximum error is within 3° for underwater sensing with quasi-static measurements. It is expected that the proposed waterproof flexible sensor can push the boundaries of wearable robotics, human locomotion, as well as their related applications.
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