Design engineers and explorers are similar in many ways. Just as an explorer sees a location on the horizon, but may not have a clear path to reach it, a design engineer often begins their R&D project with a desired outcome in mind, but rarely has a clear plan to achieve it.

Certainly, explorers have tools to help them reach their destination – a compass, binoculars, climbing gear, etc. – but chartering into unknown territory requires a willingness to throw caution to the wind. Design engineers also have a bevy of test & measurement tools at their disposal, but unlike explorers, there may be more opportunity to strategize a plan before plunging into the great beyond.

In the process of building anything, having quantifiable data on how components connect, fit, align, or seal together, is crucial to verifying a properly engineered structure. Most design engineers employ the finite element method (FEM) to analyze and understand how applied stresses may affect the material or design. However, design engineers can expose potential flaws in their FEM analysis by using advanced technologies that can capture actionable information that may not be attainable through other methods.

When it comes to measuring and analyzing interface pressure or contact on a product, device, or machine design, pressure mapping technology represents a proven R&D tool that helps design engineers conquer their challenges in route to their desired result. 

We at Tekscan have worked with hundreds of design engineers on pressure-related projects ranging from confirming press fits and seal, to ergonomic furniture design, and beyond. Even though every R&D project offers its own unique set of challenges, having certain expectations in mind can help you stay efficient through your journey.

Based on our years of experience, here are a few key considerations to have in mind before beginning your R&D pressure measurement project:

1. What is the Pressure Range You Expect to Measure?

In many cases, you may already have an idea of the amount of force or pressure you expect from your application. While testing, however, you may discover localized peak pressures that extend beyond your expectations, which could create even more challenges in your project.

One of the key advantages to using pressure mapping technology in your R&D project is the ability to adjust sensor sensitivity on-the-fly. This helps the design engineer accommodate these greater-than-anticipated peak pressures, without having to begin a new testing strategy from scratch. This article explains how to adjust sensitivity of a pressure mapping sensor, along with a more in-depth overview of the technology itself.

2. Are There any Testing Constraints – Physical or Environmental – that May Affect Your Ability to Test Pressure?

For many pressure-specific R&D projects, the difference between success and failure lies within paper-thin spaces that people generally cannot reach. High temperatures, long testing durations, the need to capture data wireless, and other factors play a role in the ability to get good, clear data.

Depending on the needs of your application, a custom pressure mapping sensor design may be what you need. This short video gives you a glimpse into the Tekscan pressure mapping sensor customization process:

3. Is the Event You Wish to Measure Static, or Dynamic/Changing?

Some pressure-specific projects may only require the ability to capture peak pressure regardless of timing. If this is the case, then pressure-sensitive film, like Fujifilm Prescale, may be a cost-effective method to deliver the results you need.

However, if there’s value to be had by capturing the entire range of pressure occurring over the total testing period, then pressure mapping technology delivers the total analysis package you need. This can be especially useful for machine alignment applications, where capturing pressure distribution changes while adjustments are made can help to eliminate operator guesswork and improve quality.

This article provides more details on how pressure film and pressure mapping technology compare.

4. How Will You Account for Other Variables – Such as an Aggressive Testing Environment – that May Affect Sensor Life?

Pressure testing environments with components that slide or grind together will certainly complicate the ability to capture data due to the damaging effects these actions can produce. It’s always important to account for ways to protect your testing tools in these cases, especially when working with an ultra-thin sensor technology.

If you’re considering pressure mapping technology for a potentially hazardous testing environment, we highly recommend consulting our experts to determine the best method to protect the sensor. 

Take a More Calculated Expedition into Your Pressure Testing Project

Equip yourself with the knowledge of how pressure mapping technology can help find solutions to your pressure-related challenges by downloading this free eBook.