DescriptionThis work aims to develop a scalable process of fabricating highly porous composite paper with tunable conductivity and put forward an open-source workflow to model a three-phase stochastic fibrous network. In the experimental studies, this work employs a foam-laying method to fabricate composite paper with carbon black as conductive fillers and cellulose fibers as the matrix. By embossing such paper, its porosity decreases while its conductivity increases. Tuning the porosity of composite paper alters the magnitude and trend of conductivity over a spectrum of concentrations of conductive particles. The largest increase in conductivity from 8.38×10-6 S/m to 2.5×10-3 S/m by a factor of ~300 occurred at a percolation threshold of 3.8 wt% (or 0.36 vol%) with the composite paper plastically compressed by 410 MPa, which caused a decrease of porosity from 88% to 42% on average. Our composite paper showed stable piezoresistive responses within a broad pressure range from 1 kPa up to 5.5 MPa for 800 cycles. The piezoresistive sensitivities of the composite paper were concentration-dependent and decreased with pressure. Composite paper with 7.5 wt% CB had sensitivities of −0.514 kPa−1 over applied pressures ranging from 1 kPa to 50 kPa and −0.215 kPa−1 from 1 kPa to 250 kPa. This piezoresistive paper with embossed patterns enabled touch sensing and detection of damage from darts and punches. Understanding the percolation behavior of three-phase composites (cellulose fibers/conductive particles/air) and their response to damage, pressure, and processing conditions has the potential to enable scalable applications in prosthetics and robotics, haptic feedback, or structural health monitoring on expansive surfaces of buildings and vehicles. Few theoretical models capture piezoresistive responses of three-phase conductive composites. To interpret the electromechanical coupling of our piezoresistive composite and provide some insight in designing customized composite, we built multiscale models to simulate nanoparticle-nanoparticle interaction and fiber-fiber interaction. We also proposed an open-source workflow for computational generation and finite-element analysis of non-woven fibrous materials. To avoid interpenetration of fibers, we generated a micro-mechanical model with curved fibers in Blender, an open-source 3D computer graphics software, and applied rigid-body physics to fibers to repel each other for stacking. We modeled the paper-making process by simulating the falling and shaking of the fibers. Then, we further analyzed the electrical properties of the fibrous network in the open-source Salome-Elmer software. Overall, the proposed open-source workflow facilitates and speeds up the generation and analysis of the non-overlapping fibrous network.