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In this paper, we report on a low-cost, environment-friendly and wearable thermal flow sensor, which can be manufactured in-house using pencil graphite as a sensing hot film and biodegradable printing paper as a substrate, without using any toxic solvents or cleanroom facilities. The hot film flow sensor offers excellent performance such as high signal-to-noise ratio (40 for an air flow velocity of 1 ms− 1), high sensitivity to airflow (53.7 mV (ms− 1)− 0.8) and outstanding long-term stability (almost no drift in 24 h). The sensor can be comfortably affixed to the philtrum of patients and measures human respiration in realtime. The results indicate that the wearable thermal flow sensors fabricated by this solvent-free and user-friendly method could be employed in human respiratory monitoring.