As physical education advances, college physical education classrooms are becoming increasingly diverse, but this development also brings security concerns. Intelligent sportswear, serving as a real-time monitoring device for human data, can enhance safety for both teachers and students. This study focuses on developing a conductive filler for flexible piezoresistive sensors using modified multi-walled carbon nanotubes (MWCNTs). Firstly, the tunneling theory and permeability effects are employed to establish a sensing mechanism model and analyze the conductivity and piezoresistive effects. Subsequently, silane coupling agents (KH550) and sodium dodecyl benzene sulfonate (SDBS) are chosen to enhance the conductive filler’s performance. Finally, smart gloves, smart insoles, and smart vests are designed for the detection of hand pressure, foot pressure, and respiratory rate. This aims to enhance safety measures in physical education classrooms. Furthermore, their performance is validated through simulation experiments. Results indicate that MWCNTs were modified with KH550 and SDBS, showing improved conductivity with higher filler concentration. KH550-SDBS-MWNT/PU material demonstrates 108.3% increased elongation at break, 9% reduction in nonlinear error, enhanced linearity, and 2.972 sensitivity increase. Displacement deviation analysis reveals load change trends based on filler concentration. Empirical analysis of smart clothing, like smart insoles, aligns sensor data with theoretical principles, highlighting the potential for flexible sensor performance enhancement. In conclusion, the modified MWCNs have demonstrated potential for enhancing the performance of flexible sensors.
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