Key Facts at a Glance

In many industrial systems, critical loads occur in places where conventional sensors simply cannot operate reliably. Consider a load-bearing mount in mobile equipment: exposed to vibration, shock, moisture, and contamination – yet expected to deliver precise measurement data for control and optimization.

Traditional sensor setups struggle in these environments. They require space, protection, and careful positioning, often adding complexity rather than solving it. This is where smart elastomers fundamentally change the approach.

By embedding sensing directly into functional materials, sensor-integrated elastomers transform passive components into intelligent system elements. Instead of adding sensors to a system, the system itself becomes the sensor – enabling real-time monitoring in mechanical systems, improved reliability, and scalable predictive maintenance with embedded sensors.

The Solution

Sensor-integrated elastomers overcome these limitations by embedding sensing capabilities directly into the elastomer component itself. This approach enables a seamless combination of mechanical function and data acquisition.

At the core of this innovation is proprietary load sensing elastomer (LSE) technology.

1. One Component, Fully Integrated

The elastomer simultaneously acts as:

• A damping element
• A sensor for force and system behavior

All sensing electronics are fully integrated into the compact, ultra-thin sensor, meaning:

• Only one external interface (cable) is required
• No separate electronics or external signal conditioning is needed
• The installation position is inherently defined by the component itself

This significantly reduces integration complexity and ensures consistent measurement positioning.

The result is a true smart elastomer – a structural component that generates data.
 

2. Ultra-Thin and Scalable Design

A key differentiator is the extremely thin sensor architecture, enabling integration where conventional sensors cannot be used:

• Sensor thickness can be below 1 mm, allowing embedding into tight geometries 
• Ideal for applications with limited installation space or strict weight constraints

In addition, the technology is highly scalable:

• Force measurement ranges from a few grams to several kilograms and beyond
• Geometry and size can be adapted to specific application requirements

This flexibility makes it suitable for both high-load industrial systems and precision applications.
 

3. Accuracy Through Integrated Algorithms

The sensor includes integrated algorithms and signal processing, directly embedded within the system.

These algorithms:

• Compensate for hysteresis, drift, and non-linearity
• Improve measurement accuracy and repeatability
• Enable stable data acquisition under dynamic loads

This ensures reliable real-time monitoring in mechanical systems, even in highly variable conditions.
 

4. Multi-Parameter Sensing and Functional Capabilities

Beyond force measurement, the system enables true multi-parameter sensing, including:

• Force (static and dynamic)
• Vibration and acceleration (up to ±16 g)
• Angular motion (gyroscopic sensing up to ±2000 dps)
• Temperature
• Cycle counts(e.g., rotations, oscillations, repetitive motion)
• Overload detection, with threshold-based warnings

This enables advanced condition monitoring with elastomers, combining multiple sensing functions into a single compact component.
 

5. Built for Harsh Operating Conditions

The elastomer encapsulation provides intrinsic protection against:

• Moisture and humidity (up to 95% rH)
• Dust and contamination
• Mechanical shock and vibration
• Temperature variations

This makes the technology ideal for applications:

• With continuous vibration
• In outdoor or industrial environments
• Where conventional sensors would require complex protection
   

6. Flexible Usage: Embedded or Standalone

While optimized for integration into elastomer components, the sensor can also be used:

• As a standalone sensor element
• Integrated into other mechanical structures
• Bonded into assemblies without full elastomer overmolding

This flexibility extends its applicability beyond classical elastomer use cases.
 

7. Manufacturing Expertise: Surviving Elastomer Processing

A critical challenge in developing sensor-integrated elastomers is the integration process itself. Elastomer manufacturing – particularly vulcanization – exposes components to high temperatures, high pressures, and chemically aggressive environments.

For conventional electronics, this process typically leads to:

• As a standalone sensor element
• Integrated into other mechanical structures
• Bonded into assemblies without full elastomer overmolding

Angst+Pfister has developed proprietary design and process know-how that enables sensors to withstand vulcanization without loss of functionality.

This includes:

• Specialized sensor architectures adapted to elastomer processing
• Robust encapsulation strategies
• Controlled manufacturing processes ensuring repeatability

This capability is a key enabler for reliable embedded sensors in mechanical components and a major technological differentiator.

 

Results and Proof of Performance 

Parameter	Conventional Sensors	Smart Elastomers (LSE-Based)
Installation space	High	Minimal
System architecture	Multiple components	Single integrated component
Overload resistance	Limited	Up to 500-1000% FS
Measurement response time	Moderate	<50 ms
Measurement capabilities	Single parameter	Multi-parameter sensing option

 

Beyond component-level specifications, performance is validated through application-specific testing. Angst+Pfister operates dedicated in-house test rigs, enabling:

• Validation under real operating conditions (load, vibration, temperature)
• Calibration and optimization for specific applications
• Verification of long-term behavior, including cycle counts and overload scenarios

This ensures that solutions are not only conceptually sound but tested and proven functional before deployment.

 

Conclusion

Smart elastomers represent a fundamental shift in mechanical system design. By integrating sensing directly into functional materials, they eliminate the need for separate sensors while improving robustness and simplifying system architecture.

With features such as:

• Ultra-thin, scalable design
• Fully integrated electronics with a single interface
• Multi-parameter sensing and embedded algorithms
• Reliable performance in harsh environments

combined with proprietary manufacturing expertise and validation through in-house test rigs – these systems deliver not only integration advantages but also proven reliability under real-world conditions.

As systems continue to evolve toward higher integration and intelligence, sensor-integrated elastomers will play a key role in enabling efficient, data-driven engineering solutions.

 

---

About the Author 

Michael Tester is the Head of Sensor Design Engineering at Angst+Pfister Sensors and Powers, bringing over 10 years of expertise in merging advanced technology with material science. He specializes in developing integrated sensor platforms that transform passive mechanical components into intelligent, data-generating systems for harsh industrial environments.