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Calibrate the individual sensor in the setup where it will be used: condition it according to its manufacturer’s instructions, apply several known loads across the intended range, and map its electrical output to force or pressure. Keep contact geometry, fixture, temperature, and measurement timing consistent. A calibration curve alone is not enough if the application involves changing loads or long holds; check loading-versus-unloading behavior and drift too.
What calibration does—and what it does not
Calibration relates a sensor’s electrical output to a known engineering quantity, such as force or pressure. The resulting curve applies to the particular sensor and measurement setup, not to every sensor of the same type. Tekscan’s FlexiForce Rev H manual recommends applying multiple known loads across the expected range and plotting force against conductance for that sensor family.
Decide first whether the quantity you need is force or pressure. A sensor’s force reading does not become pressure automatically: pressure depends on the effective contact area and how the fixture distributes the load. If the area or load distribution changes between calibration and use, the same electrical output may no longer represent the same pressure.
Set up the calibration to match the application
Before collecting data, specify the range and the physical conditions that determine how the sensor is loaded. Avoid a fixture that loads outside the sensing region or carries part of the applied force. Tekscan advises even loading over the sensing area, using the same interface for calibration and testing, and avoiding sensor saturation.
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- High-precision weighing: Strain gauge sensing structure, offering excellent linearity and minimal temperature drift, ensuring accurate and stable weighing readings
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- Quantity and range: Set the expected minimum and maximum force or pressure. Keep the reference loads within the usable range.
- Contact and support: Match the load footprint, backing surface, mounting, curvature, and fixture to intended use.
- Environment: Calibrate at the application temperature. Record relevant environmental conditions; do not assume a curve made under different conditions transfers unchanged.
- Timing: Decide how long after applying a load the reading will be taken, and use the same wait in calibration and operation.
Condition the sensor before calibration
Mechanical conditioning can affect the readings collected afterward. Follow the instructions for the specific sensor rather than applying another model’s procedure. For example, Tekscan’s FlexiForce Rev H manual directs users to apply 110% of the test weight, allow the sensor to stabilize, unload it, and repeat the sequence four or five times. That procedure is specific to the manual and should not be assumed to suit every stretchable sensor.
Collect reference readings and build the curve
- Apply known loads: Use deadweights or a suitable test device to apply several reference forces spanning the intended range. Ensure the force reaches the sensing area in the same way as it will in use.
- Record each point: Log the reference load, raw electrical output, temperature, time after load application, and whether the load is increasing or decreasing.
- Repeat where appropriate: Repeated calibration runs can reveal variability. A 2017 study of flexible force sensors for compression-therapy monitoring calibrated each sensor five times and averaged the resulting curves; that is an example from that study, not a universal requirement.
- Fit the relationship: Plot the reference quantity against the chosen output variable. Use linear interpolation only if the measured response supports it; otherwise use a suitable model and document the calibration range and residual error. The force-versus-conductance plot in the FlexiForce manual is specific to its sensor.
Keep the raw measurements as well as the fitted curve. Without the reference points and their conditions, it is difficult to tell whether a converted reading is inside the calibrated range or whether a later change reflects the sensor, fixture, or environment.
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- High-precision weighing: Strain gauge sensing structure, offering excellent linearity and minimal temperature drift, ensuring accurate and stable weighing readings
- Compatibility with multiple specifications: Comprehensive range of capacities, supporting various signal outputs, and capable of interfacing with instruments and PLC data acquisition devices
- Robust and Easy to Install: Alloy elastomer construction, capable of withstanding short-term overloads, multiple standard mounting configurations for easy installation and removal
- Suitable for Multiple Applications: Used in industrial scenarios such as hopper scales, tensile testing, assembly line checkweighing and tank weighing
- Comprehensive Support Services: Supplied with calibration cables and installation guidance
Verify accuracy, hysteresis, and drift
When feasible, test the fitted curve with known loads that were not used to construct it. Compare converted readings with those references across the range and report the tested range and conditions. This is a practical verification approach, not a universal acceptance standard; the sources here do not establish one accuracy threshold for all stretchable pressure sensors.
Two time- and direction-dependent effects deserve separate checks when they matter to the application:
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- Hysteresis: At the same force, output can differ depending on whether load is increasing or decreasing. If the sensor will experience both directions, collect and compare readings during loading and unloading.
- Drift: Under a constant force, output can change over time. Hold a realistic load for a duration relevant to use and track the reading rather than relying only on a quick load-and-release test. The 2017 study’s eight-hour static test and repeated dynamic cycles illustrate why a short calibration may miss behavior that appears over time.
Tekscan’s 2010 manual lists specifications for standard FlexiForce sensors: linearity error of ±3%; repeatability of ±2.5% of full scale at 80% applied force after conditioning; hysteresis below 4.5% of full scale at 80% applied force after conditioning; and drift below 5% per logarithmic time scale at a constant load of 90% of sensor rating. These are product-manual figures for that sensor family, not performance claims for stretchable pressure sensors generally.
Independent reader supportYour contribution helps us test, update, and keep practical guides available for everyone.When to recalibrate—and how to compare procedures
Recheck calibration after changing the sensor, fixture, contact geometry, mounting, or operating temperature, or when readings show a baseline change. No universal recalibration interval is established by the sources cited here; choose one based on the application’s conditions and observed stability.
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When comparing sensors or calibration methods, look beyond a single accuracy figure. The reliability review notes inconsistent reporting of drift, hysteresis, and environmental test conditions across the field. Compare the factors that determine whether results are meaningful for your use:
- Usable force or pressure range
- Loading geometry, including curvature and contact footprint
- Temperature and humidity test conditions
- Output during loading versus unloading
- Drift over the expected measurement duration
- Repeatability across cycles
- Residual error or accuracy against known reference loads
The FlexiForce manual and the 2017 compression-therapy study concern specific sensors and test contexts. Neither defines performance requirements for all stretchable pressure sensor designs.
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