Frequently Asked Questions

ShuntMode sensors use two substrates: one printed with interdigitated conductive fingers, the other with a force-sensing ink layer. When pressed together, the FSR material bridges (shunts) across the conductive fingers, decreasing resistance. ShuntMode sensors tend to have higher initial resistance and are well suited for on/off detection and proportional force measurement.

ThruMode sensors have conductive pads on each substrate, each overprinted with FSR material. When pressed, current passes through the FSR material from one pad to the other. ThruMode devices generally offer a wider dynamic range and more gradual force-resistance curves, making them ideal for applications requiring fine force resolution.

For a detailed comparison, see our FSR 101 page.

Load cells and strain gauges are precision instruments designed for highly accurate, repeatable force measurement — and their cost reflects that. FSRs are designed for applications where you need a thin, flexible, cost-effective sensor that provides proportional force feedback without laboratory-grade accuracy.

FSRs excel where load cells cannot: inside a shoe insole, under a drum head, across the surface of a car seat, embedded in a robotic gripper pad, or anywhere space, weight, and cost are constrained. Typical FSR repeatability is ±2-5%, which is more than sufficient for human-interface and threshold-detection applications.

FTR is a bulk elastomeric material that changes resistance when compressed. Unlike thin-film FSRs, FTR responds to volumetric compression throughout its thickness, giving it a greater dynamic range. FTR can also be formed into compound curves and three-dimensional shapes.

FTR is particularly useful in applications requiring conformable sensors, 3D surfaces, or very high force ranges. FTR pills — small discs of the material — can be used as individual sensing elements in custom mechanical housings.

Standard FSR configurations typically operate from about 20 grams to several kilograms. The specific range depends on the sensor construction — the FSR ink formulation, electrode geometry, spacer height, and the mechanical actuation system surrounding the sensor all influence the effective range.

For lighter forces (under 100g), the spacer design and overlay stiffness are critical. For heavier forces (above 5kg), mechanical actuators that concentrate force onto the sensing area can extend the useful range significantly. We can design sensors for your specific force range requirements.

Consider what your application needs most. ShuntMode sensors are simpler to manufacture in custom shapes and sizes, and they work well for binary (press/no-press) detection and moderate-resolution force measurement. If you need to detect presence, trigger thresholds, or measure relative force levels, ShuntMode is often the right choice.

ThruMode sensors offer smoother, more gradual force-response curves and wider dynamic range. If your application requires fine control over force levels — like a musical instrument controller, precision grip feedback, or proportional speed control — ThruMode is generally preferred. Contact us and we can recommend the best configuration for your specific needs.

The most basic approach is a voltage divider: connect the FSR in series with a fixed resistor between your supply voltage and ground, then read the voltage at the junction with an analog-to-digital converter (ADC). The fixed resistor value sets the sensitivity range — a larger resistor increases sensitivity to light forces, while a smaller resistor extends the range to heavier forces.

For better performance, an op-amp configured as a current-to-voltage converter provides a more linear output and eliminates the loading effects of a simple divider. Our tutorials include complete circuit examples with component values for common configurations.

FSR resistance values shift with temperature — typically resistance decreases as temperature rises. The magnitude of this effect depends on the ink formulation and sensor construction. For most room-temperature applications (15-35°C), the effect is minor and easily compensated in software.

For applications in extreme environments (automotive under-hood, outdoor, industrial), we formulate inks with improved thermal stability. Our LowDrift technology specifically addresses long-term resistance stability, including temperature-related drift. If your application operates outside normal room temperatures, let us know during the design phase so we can select appropriate materials.

The mechanical integration is often the most critical part of FSR system design. The sensor should be mounted on a firm, flat surface with the force applied through a consistent actuation area. Pressure-sensitive adhesive (PSA) on the back of the sensor is the most common attachment method.

Key design considerations: ensure the actuation force is distributed evenly across the sensing area, avoid point loads on the edge of the sensor, and consider how the overlay material (the thing the user presses against) affects force transmission. A compliant rubber overlay can improve consistency, while a rigid puck concentrates force for higher-sensitivity applications. Our engineering team can review your mechanical integration as part of a custom sensor project.

Yes. Our XactFSR product line provides pre-coated force-sensing material in sheet form. You can cut it to any shape with scissors, a craft knife, a die cutter, or a laser. Combined with a conductive substrate (which we also supply), you can build custom FSR sensors without screen-printing equipment or materials science expertise.

XactFSR is ideal for rapid prototyping, small production runs, educational use, and applications where sensor geometry changes frequently. For high-volume production, we recommend transitioning to screen-printed sensors for better consistency and lower per-unit cost.

Prototype quantities typically take two to four weeks from finalized design to delivery. Production orders depend on volume and complexity, but first articles usually ship within four to six weeks. For urgent timelines, we can often accelerate prototyping. Contact us with your timeline and we'll give you a realistic schedule.

We handle everything from single prototypes to production runs in the millions. Our in-house lab handles prototyping and low-to-mid volume production. For high-volume programs, we work with ISO 9001-certified manufacturing partners who operate under our process specifications. There is no minimum order for custom design work.

FSR lifetime depends heavily on the application — specifically the force magnitude, frequency of actuation, and environmental conditions. In typical human-interface applications (button presses, grip sensing), FSRs routinely survive millions of actuation cycles. Static load applications (like seat occupancy detection, where the sensor is under continuous force) require careful material selection to manage long-term drift.

Our LowDrift technology was developed specifically to address long-term stability under sustained loading. If your application involves continuous or near-continuous force, let us know so we can recommend appropriate materials and construction.

Yes. We offer standard sensor samples for evaluation, and our XactFSR materials let you experiment with sensor geometry before investing in custom tooling. Visit our FAQ Downloads App Notes Case Studies Request Samples page or contact us to discuss your evaluation needs.

Absolutely. We don't just sell sensors — we help you integrate them successfully. That includes guidance on mechanical mounting, circuit design, signal conditioning, firmware considerations, and testing methodology. Our engineering team has nearly five decades of experience solving FSR integration challenges across every major industry.