Abstract

Abstract Due to its excellent durability and steady mechanical qualities, three‐dimensional porous polyurethane foam (PUF) presents a wide range of possibilities for flexible piezoresistive sensors. Its extreme flammability, poor electrical conductivity, and susceptibility to outside factors present serious difficulties, though. In this study, a waterborne polyurethane‐coated flexible PUF sensor that incorporates reduced graphene oxide (RGO) and polyaniline (PANI) through a methodical, step‐by‐step dip‐coating methodology is successfully developed. The final product has a water contact angle of 133°, which improves its ability to adapt to a variety of environmental circumstances. Flexible graphene sheets are incorporated to improve heat resistance and flame retardancy, and PANI and RGO provide strong bonding to the PUF framework, ensuring outstanding structural stability even after 1500 cycles. The flexible foam sensor shows promise for use in flexible piezoresistive sensors and electronic skin due to its remarkable strain monitoring range of up to 70%, quick response time of 0.39 s in sensitivity experiments, and adaptability to different physical activities like walking and gesturing.