This article presents a method for the development of an exhalation sensor consisting of a printed conductive cantilever that was embedded into the sponge part of a headset microphone. The cantilever was printed onto the sponge surface by using a printing method based on a technique known as Lift-On Offset Printing and was improved to achieve strong adhesion between the ink layer and the roughness of the sponge surface. The sensor clearly changed its capacitance in correspondence to the user’s exhalation distinguishing the user’s states. The developed sensor can be used to monitor a user’s health condition for improved safety.