Thin-Film Sensors Require No Additional Installation Space

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Machine downtime, quality deviations, and wear-related failures rarely occur without warning signs, yet these often go undetected. Fraunhofer Institute for Surface Engineering and Thin Films (IST) is making such hidden conditions visible with integrated thin-film sensor technology that measures directly on the component surface.

At the Sensor+Test 2026 trade fair, taking place June 9–11 in Nuremberg, IST will present an overview of condition monitoring applications in the Condition Monitoring Area (Hall 1, Booth 1-551/2). The institute will demonstrate how thin-film sensors are integrated into components and tools to capture pressure, force, and temperature data.

The continuous acquisition of these data enables real-time monitoring of machine conditions and early detection of changes. This provides the basis for maintenance planning. At the same time, the sensor data open up new possibilities for process control.

One feature of IST’s thin-film sensor technology is its installation-space-neutral integration. The sensors can be incorporated into highly stressed functional areas without affecting component geometry or functionality. Thanks to their high wear resistance, they deliver measurement data even in applications where conventional sensor systems reach their limits.

Such applications are already being used today in the optimization of machine elements, machining processes, and plastic injection molding. Looking ahead, IST expects the importance of such sensor data to continue increasing, particularly in combination with artificial intelligence and machine learning, which enable more comprehensive use of the information.

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