A Flow Sensing Device Formed Exclusively by Employing Additive Manufacturing for On-Site Fabrication Aboard a Ship

Area of Science:

• Additive Manufacturing
• Sensor Technology
• Fluid Dynamics

Background:

• Traditional sensor manufacturing requires external facilities, limiting on-site fabrication.
• Remote industrial environments, such as ships, face challenges in sensor deployment and maintenance.
• Vortex shedding is a known principle for fluid flow measurement.

Purpose of the Study:

• To design, fabricate, and test a novel air-flow sensor.
• To exclusively utilize additive manufacturing for on-site sensor production.
• To demonstrate a low-cost, robust, and simple sensor solution.

Main Methods:

• Employed Fused Deposition Modeling (FDM) 3D printing for integrated fabrication.
• Manufactured flow-shaping housing, piezoresistive sensing element, and electrical pads in a single step.
• Utilized standard soldering for connection to readout circuitry.

Main Results:

• Successfully fabricated a functional prototype air-flow sensor.
• Validated the sensor's proper functionality through preliminary characterization.
• Demonstrated the feasibility of single-step, on-site manufacturing.

Conclusions:

• Additive manufacturing enables the creation of complex sensors in remote locations.
• The developed vortex shedding sensor offers a cost-effective and robust alternative.
• Potential applications exist in shipbuilding and other industrial sectors requiring on-site measurement capabilities.