Challenges and Opportunities for Laser-based Additive Manufacturing of Strain Sensors

The use of printing and laser technology for additive manufacturing allows for rapid creation of individual sensor structures. Digital production technologies may substitute cost-intensive manual application processes of strain gauges. The development of additive production of individualized, component-connected sensors is shown. Necessary layers and structures of different materials are printed directly onto the component and then laser-treated (sintered, melted, hardened, etc.). In the case of strain gauges the insulation layer, the measuring grid and the encapsulation are applied. In contrast to conventional thermal processes, no complete heating of the component (furnace) or irradiation of the entire surface (flash lamps) is necessary. The energy deposition can be controlled in terms of time and location. This makes the selective coating of temperature-sensitive components possible. A new process chain for an automated way of sensor creation and application offers the widespread use of strain sensors in a new generation of smart products.