Advantages, Working Principle, and How They Compare to Thick Film Sensors
Sputtered thin film pressure sensors are used to measure pressure in many fields, especially in harsh environments. They are widely used in aerospace, ships, trains, vehicles (such as forklifts and cranes), and hydraulic equipment, because of their high accuracy, strength, and reliability.
In this article, we explain:
How these sensors work
Why they are better than other types
How they compare with thick film pressure sensors
What Is a Sputtered Thin Film Pressure Sensor?
These pressure sensors are made using thin film technology, where very thin layers of material are deposited onto a stainless steel diaphragm. These layers form tiny resistors that change when pressure is applied.
When the diaphragm bends under pressure, the resistors change their values. These changes are detected using a Wheatstone bridge circuit, and the signal is converted into a standard electrical output. This output tells us the exact pressure value.
Key Advantages of Sputtered Thin Film Pressure Sensors
 1. High Accuracy and Reliability
Thin film layers are made with precise thickness, allowing very accurate pressure measurement.
Excellent repeatability and long-term stability.
 2. Excellent Performance in Harsh Conditions
Sensors are fully welded, with no rubber seals and no filling oil.
Can resist strong vibrations, shocks, corrosion, and high peak pressures without leaking.
 3. Wide Temperature Range
Can operate from -40°C to 125°C, or even from -55°C to 150°C upon request.
Made with laser trimming and semiconductor technology to improve performance across temperatures.
 4. High Frequency Response
Because the pressure acts directly on the stainless steel core, without a diaphragm or fluid inside, the sensor responds very quickly to pressure changes.
 5. Small and Compact
Perfect for applications with limited space, such as mobile machinery or compact hydraulic systems.
Herausforderungen und Hinweise
Die Verbindung zwischen Sensorelement und Gehäuse muss hochwertig sein – schlechte Verbindung kann bei Dauerbelastung zum frühen Ausfall führen.
Die Herstellung erfordert teure Vakuumanlagen und Reinräume.
Nur erfahrene Hersteller wie Macsensor können eine kontaminationsfreie Produktion mit hoher Prozessstabilität garantieren.
Challenges and Considerations
The bonding quality between the sensor and its housing is very important. Poor bonding can lead to early failure.
Manufacturing these sensors needs expensive sputtering equipment and a clean room to avoid contamination.
Only specialized manufacturers with high-quality processes, such as Macsensor, can ensure stable and reliable production.
Real-World Use
The thin film pressure sensors are designed to handle:
Cavitation
Water hammer
High pressure spikes
Strong vibration
Unstable power supply
These problems often appear in construction machines, agricultural equipment, and industrial hydraulic systems. The sensors are built to perform reliably even under these tough conditions.
Thin Film vs. Thick Film Pressure Sensors
Feature | Thin Film Sensors | Thick Film Sensors |
Film Thickness | ~0.1 micrometer or less | Much thicker (several micrometers) |
Manufacturing | Metallic film in vacuum | Fired metal-glass paste |
Accuracy | Very high | Lower |
Temperature Stability | Excellent | Moderate |
Cost | Higher | Lower |
Best Use | Precision & demanding environments | Cost-sensitive, less critical applications |
The Future of Thin Film Sensors
With ongoing research and development, sputtered thin film pressure sensors are becoming:
Smaller
Smarter (digital & intelligent)
More integrated
Their role in modern vehicles, industrial machinery, and smart systems will continue to grow.
👉 Learn more about our pressure transmitters and find the right solution for your application.
