Molded Elastic Sensors: A Unique Measurement Range for New Applications

Molded Elastic Sensors: A Unique

Measurement Range for New Applications
Sponsored by Sateco AG Dec 6 2022
Reviewed by Olivia Frost

Humans are increasingly interacting with machines in domains like medical

technology, industrial production, and well-being. Machines collaborate and support
humans in improving their performance or health conditions. In some cases, the
machine is wearable and comes into direct contact with the human body, such as
exoskeletons, prosthetic and orthotic devices.

In this instance, the machine and its components adapt to the three-dimensional shape of
the human body. Force sensors can aid in making interactions more intuitive, protect
humans and their surroundings from misuse, and ensure comfort and safety.

Such sensors should ideally fit perfectly between the machine and the human body, be
delicate and skin-friendly, and be capable of dealing with enormous tolerances inside
complicated, three-dimensional systems under a variety of environmental conditions.

This will enable consistent measuring settings in which the sensor is constantly exposed to
the force interaction between the machine and the body. Furthermore, it prevents the
sensor signal from saturating under high environmental or mechanical conditions due to
overload, enhancing the reliability of the sensor system.

Electronic Skin
Human skin has an extraordinarily fine and complex sensor system for perceiving touch
and forces, allowing individuals to function intuitively and accurately. The mechanical
properties of silicone are extremely similar to those of skin. Silicone can be utilized as a
mechanical transducer for forces and pressures by appropriately engineering the form and
conductivity of the material.

Force sensors based on elastomers were pioneered in the late 1960s1-4 and have been
continuously improved throughout the subsequent decades. The sensor mentioned here is
based on Fraunhofer Gesellschaft’s work.5

The current silicone sensor is made up of three elastic conductive layers that are placed on
top of each other. Each layer comprises three-dimensional flexible spacers that divide the
layers when stacked.

P
Saved from URL: https://www.azosensors.com/article.aspx?ArticleID=2697
1
/9
Molded Elastic Sensors: A Unique Measurement Range for New Applications

The spacers between the layers are formed in the shape of tiny membranes. They operate
as elastic springs and hold the layers in place. This results in the formation of a soft,
compressible sensing capacitance that can be electronically measured.

When a force or pressure is exerted on the sensor, the conductive layers move in a
specified direction toward each other, decreasing the distance between the layers (Figure
1a). This results in an increase in the electrical capacity of the silicone sensor, which the
electronics can then measure.

It can also accurately analyze the sensor signal even with high-impedance elastomer
material by building the measurement electronics as an AC voltage divider.

When the load is removed from the sensor, the spring elements reset the sensor, and the
measurement signal is returned to its original state.

P
Saved from URL: https://www.azosensors.com/article.aspx?ArticleID=2697
2
/9
Molded Elastic Sensors: A Unique Measurement Range for New Applications

Figure 1. Working principle. (a) Sensor appearance incl. cross-sectional view (b) typical
measurement curve. Image Credit: Sateco AG

A typical capacitive measuring signal from a silicone sensor is shown in Figure 1(b).

Due to the material’s viscoelastic characteristics, some hysteresis is detected. By modifying

the material hardness and the shape of the spacers between the layers, the relationship
between load force and resultant capacitance can be tuned for the sensor application.

The higher the maximum load that is applied, the harder the material and the stiffer the
spacers. Most experience is now available with sensors ranging in length from 10 to 20
mm, which can estimate forces of 10 N with an accuracy far below 1 N.

Tested Durability
When compared to other elastic materials, silicone’s strong elastic qualities allow it to
tolerate a very high number of load cycles. The results of a mechanical durability test on a
sensor with a diameter of 16 mm and a nominal load of 10 N are shown in Figure 2.

In this test, the sensor was subjected to 500,000 repeated load cycles of 20 N, which is
double the nominal maximum load. Additionally, further sensor testing was performed inside
a climate chamber based on typical automotive industry standards.

P
Saved from URL: https://www.azosensors.com/article.aspx?ArticleID=2697
3
/9
Molded Elastic Sensors: A Unique Measurement Range for New Applications

P
Saved from URL: https://www.azosensors.com/article.aspx?ArticleID=2697
4
/9
Molded Elastic Sensors: A Unique Measurement Range for New Applications

Figure 2. Durability load test of a silicone force sensor. Image Credit: Sateco AG

Silicone sustains its elastic ability throughout a very wide temperature range, typically −40
°C to +200 °C, and is thus suited for application in harsh weather circumstances. In the
climate tests, the temperature is cycled between -40 °C and +85 °C during the cyclic load.

Furthermore, humidity is added up to 90% RH. Under these conditions, silicone sensors
were subjected to 200,000 load cycles. Depending on the environmental conditions, aging
is observed in the form of drift. A reference sensor can compensate for this drift.

A spatial resolution can be realized by using multiple sensors at the same time, for
example, to detect the direction of the force.

Proven Manufacturing Processes

The silicone sensor’s base material is an electrically conductive solid silicone with a
hardness of 60 Shore A. Carbon-based particles are used to increase conductivity. The
crosslinked solid silicone combination has a conductivity of more than 0.10 Siemens/cm
and is widely accessible commercially. The sensor is shaped under high pressure and
temperature using a compression tool.

The compression process enables the processing of highly filled, very viscous silicone
material and three-dimensional shaping in just one step. The molding process produces
both the spring components that support the individual sensor layers and the overall shape
of the completed sensor. The crosslinked silicone part is removed from the mold and folded
into the three-layer configuration that is shown in Figure 3.

The electrical connection of the sensor can be created using a connector that is bonded to
the conductive silicone. In contrast to printing, compression molding allows for the creation
of true three-dimensional free-form surfaces. This opens up new possibilities for product
design, such as ergonomic use.

P
Saved from URL: https://www.azosensors.com/article.aspx?ArticleID=2697
5
/9
Molded Elastic Sensors: A Unique Measurement Range for New Applications

Figure 3. Assembly process of the silicone sensor composed of molding and printing.
Image Credit: Sateco AG

Application Examples
The silicone sensor has a strong elastic deformability in the force or pressure direction. As
a result, it can be easily incorporated into soft materials like textiles and foams. Due to its
elasticity, it can provide mechanical preload to the system. This facilitates assembly,
particularly in curved and intricate constructions. As a result, the silicone sensor is
appropriate for use in automated processes.

For mobile robots and portable exoskeletons, weight is very crucial. Object detection can
be assisted by force sensors on grippers. According to research, robots that must recognize
unknown objects require “tactile” features such as object rigidity in addition to image
recognition.

As the silicone sensor is analogous to a soft spring, it can be utilized to accurately assess
the stiffness of objects.

Force sensors in robots and exoskeleton feet assist in maintaining balance. The sensor is
useful in medical technology for controlling prostheses and sensing pressure points on the
soles of the feet and pressure bandages. One recent example relates to a wearable
neuroprosthesis that helps people with limited mobility move their paralyzed limbs.6

As shown in Figure 4, silicone force sensors are incorporated into the sole of a shoe to offer
data on walking behavior. An AI-based algorithm that drives a system of neuromuscular
electrostimulation electrodes then evaluates this data.

P
Saved from URL: https://www.azosensors.com/article.aspx?ArticleID=2697
6
/9
Molded Elastic Sensors: A Unique Measurement Range for New Applications

Figure 4. Smart show for AI-driven neuroprosthesis. The location of the force sensor inside
the sole of the shoe is indicated by green and blue dots. Image Credit: Kurage AG

As a result, the system is capable of duplicating functional movements in a personalized

and safe manner, compensating for deficiencies in the movement apparatus’s sensomotoric
performance. The sensor’s flexible form allows for excellent sensor integration in the shoe,
and force distribution on the foot can be monitored across a wide area.

As a result, a dependable signal is produced, allowing for the high force resolution required
by the AI algorithm to function properly. The neuroprosthetic device is currently undergoing
clinical testing.

Samples of silicone sensors, comprising evaluation electronics and software for viewing
measurement data, are readily available for testing (Figure 5).

P
Saved from URL: https://www.azosensors.com/article.aspx?ArticleID=2697
7/9
Molded Elastic Sensors: A Unique Measurement Range for New Applications

Figure 5. Silicone sensor starter-kit composed of sensor, electronics and graphical user
interface. Image Credit: Sateco AG

Summary
The industrialization of silicone force sensors is currently underway, and orders for a few
thousand parts have already been fulfilled. Sateco has demonstrated various examples of
robotics and medical technology applications that warrant the use of soft silicone sensors.

References
1. National Research Development Corp., German Patent DE 1,916,496, March 1969
2. Uniroyal, US Patent US 3,875,481, April 1975
3. Semperit, German Patent DE 2,800,844, January 1978
4. Key Concepts, European Patent EP 286,747, April 1987
5. Fraunhofer Gesellschaft, European Patent EP 2,698,616, August 2013
6. Kurage, Lyon, France, URL: www.kurage.fr

This information has been sourced, reviewed and adapted from materials provided by
Sateco AG.

For more information on this source, please visit Sateco AG.

P
Saved from URL: https://www.azosensors.com/article.aspx?ArticleID=2697
8
/9
Molded Elastic Sensors: A Unique Measurement Range for New Applications

Sateco AG

Address

Sonnenbergstrasse 72
Schwerzenbach
8603
Switzerland

Phone: +41 (44) 905 62 62

Visit Website

Sateco is one of the world's leading manufacturers of high-precision silicone keypads and
silicone sensors. As a Swiss family company, we employ roughly 800 employees at our
locations in Europe, the U.S., and Asia. For over 20 years, we have been serving
customers such as highly specialized system and component manufacturers from many
different industries, the best in their field.

World-renowned companies trust in the know-how and expertise of Sateco. The Sateco
brand stands for quality, cooperation, innovation, and internationality. Our corporate culture
is based on these concepts, and we put it into practice when developing and producing our
products, when communicating with our customers and suppliers and, of course, with each
other here at Sateco.

And we do so at every subsidiary all across the globe. Perhaps our customer's customers
and end customers are unaware that Sateco is found in their automobiles, buildings, or
household appliances, but they definitely experience the modern benefits with all their
senses, day after day.

P
Saved from URL: https://www.azosensors.com/article.aspx?ArticleID=2697
9
/9