In the era of rapidly evolving wearable technology, the quest for flexible and highly sensitive sensor materials has led to the exploration of aerosol jet printing as a cutting-edge fabrication technique. Here, the development and characterization of a fully aerosol jet printed strain sensor on a stretchable substrate is presented. The functional component of the sensor is the PDMS polymer mixed with the highly conductive CNT, which exhibits strain-dependent resistivity. The sensor is printed on stretchable substrate and performs across a large linear responsive range of 0–100% strain and a wide strain detection range of ∼ 150%. By optimizing CNT concentrations, we produced a conductive stretchable thin film that demonstrates stable resistance changes under strain. This material shows excellent potential as a strain sensor for human movement applications, offering enhanced durability, flexibility, and sensitivity. The development of these advanced strain sensors promises significant advancements in biomedical engineering and wearable sensor technology, enabling real-time monitoring and diagnostics.