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Fast Prototyping Ceramic Gas Flow Sensors for Harsh Operating Conditions.
Andrey Kasenko1, Pavel Shchur1, Ekaterina Anatolevna Drach1
1INTER Limited Liability Company, 115201 Moscow, Russia.
Micromachines
|February 27, 2026
Summary
This study presents a simple, affordable ceramic gas flow sensor (CGFS) technology for harsh environments. The developed CGFS can be rapidly prototyped and accurately measures gas flow under demanding conditions.
Area of Science:
- Materials Science
- Sensor Technology
- Engineering
Background:
- Harsh operating conditions necessitate robust gas flow measurement solutions.
- Existing technologies may be complex or expensive for mass production.
- Need for adaptable and rapidly manufacturable sensors.
Purpose of the Study:
- To develop a cost-effective and simple technology for mass production of ceramic gas flow sensors (CGFS).
- To evaluate material compatibility, processing speed, and flexibility for optimal sensor design.
- To test the performance of the developed CGFS under simulated harsh operating conditions.
Main Methods:
- Exploration of material compatibility for ceramic gas flow sensors.
- Development of a rapid prototyping process for CGFS.
- Testing of the manufactured CGFS in conditions mimicking real-world harsh environments.
Main Results:
- A simple and affordable CGFS technology suitable for mass prototyping was developed.
- The CGFS was designed and manufactured within days.
- The sensor demonstrated gas flow measurement capabilities from 0.21 m/s to 1.25 m/s.
- Constant power consumption of 152 mW at 346 °C was achieved.
Conclusions:
- The developed CGFS technology offers a viable solution for measuring gas flow in harsh conditions.
- The technology's simplicity and speed enable fast prototyping and mass production.
- The sensor's performance meets requirements for applications in demanding environments.
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