The Tool Desk
Outbyte Driver Updater FREEScan for outdated or missing drivers - takes under a minuteDriver Scan →Outbyte PC Repair FREERepair Windows errors before they cause bigger problemsFix Now →Calibrate the sensor in the setup and conditions where you will use it: condition it as its manufacturer directs, apply several known loads across the intended range, and record the electrical output alongside the reference load. Keep the contact area, fixture, temperature, and reading time consistent. If loads will rise and fall or remain in place, check hysteresis and drift as well as the initial calibration fit.
What calibration does—and what it does not
Calibration maps a sensor’s electrical output to a known force or pressure using reference loads. The resulting relationship belongs to the particular sensor and measurement setup, not to every sensor of the same type. For example, Tekscan’s FlexiForce manual recommends applying multiple known loads across the expected range and plotting force against conductance; that method is specific to the FlexiForce sensor family, not a universal curve for stretchable pressure sensors. Tekscan FlexiForce Sensor User Manual, Rev H.
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Decide whether your desired measurement is force or pressure. A sensor that measures force does not automatically measure pressure: pressure requires a known effective contact area, and the fixture must distribute the load over that area as intended.
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Define the range and measurement conditions
Identify the minimum and maximum loads you expect, the contact footprint, backing surface, mounting and curvature, operating temperature, and how long after applying a load you will read the sensor. Keep the test interface consistent with the eventual application. Uneven loading, a fixture that carries part of the load, or force applied outside the sensing region can distort the calibration. Avoid loading beyond the sensor’s usable range or into saturation. Tekscan’s manual emphasizes even loading over the sensing area and matching the calibration setup to the testing setup.
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Condition the sensor according to its own instructions
Mechanical conditioning can affect the response. Follow the instructions for your exact sensor model rather than adopting a procedure from another sensor. As one model-specific 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 four or five times. That instruction is not established as appropriate for all stretchable sensors.
Use known reference loads
Apply known forces with deadweights or a suitable test device whose range and fixture match the sensor and intended measurement. At each point, record the reference load, raw electrical output, temperature, time after loading, and whether the load is increasing or decreasing. Use several points spanning the expected range rather than relying on a single point. Tekscan recommends multiple loads; a 2017 study of flexible force sensors calibrated each sensor five times and averaged the resulting curves. Evaluation of Flexible Force Sensors for Pressure Monitoring in Treatment of Chronic Venous Disorders (2017).
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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
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- 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
Fit the calibration and check it independently
Plot the reference force against the electrical output variable you intend to use. For the FlexiForce example, the manual uses force versus conductance. Use a linear conversion only if the measured response supports it; otherwise, use a suitable fitted curve or interpolation over the calibrated range. Record the usable range and the fit’s residual error so that a converted value is not presented as valid outside the tested conditions.
When feasible, reserve known loads that were not used to build the curve and compare their readings with the converted values. This is a practical verification method, not a universal standard or a published acceptance threshold for stretchable sensors. Report the range, setup, and conditions under which the verification was performed.
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Check loading direction, repeatability, and time drift
Hysteresis: compare loading with unloading
Hysteresis means the output at a given force differs depending on whether the force is increasing or decreasing. If the application has changing loads, collect points in both directions and compare the readings at matching reference loads. A single loading curve may not represent unloading behavior. Tekscan reports hysteresis below 4.5% of full scale at 80% applied force after conditioning for its standard FlexiForce sensors; this is a product specification, not a general property of stretchable sensors.
Repeatability: repeat the same loading cycle
Apply the same loads repeatedly and compare the resulting outputs or calibration curves. Differences across cycles indicate how consistently the sensor and setup reproduce a reading. Tekscan specifies repeatability of ±2.5% of full scale at 80% applied force after conditioning for its standard FlexiForce sensors. In the 2017 flexible-sensor study, each sensor was calibrated five times and the curves averaged; that procedure is an example, not a requirement for every application.
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Drift: hold a load and observe the output
Drift is a change in output while the applied force stays constant. If your sensor will experience sustained pressure, monitor it for a realistic duration rather than assuming an immediate reading remains stable. The 2017 study included an eight-hour static test, illustrating the value of long-duration evaluation; that test duration is not a universal requirement. Tekscan specifies drift below 5% per logarithmic time scale at a constant load of 90% of the sensor rating for its standard FlexiForce sensors.
Timing matters even during ordinary calibration. Tekscan recommends calibrating at the application temperature, while the 2017 study recorded calibration points after a defined wait and separately tested prolonged static loading. Use and document a consistent delay between applying a load and recording output, especially if the application depends on readings taken after a specific settling period.
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When to recalibrate and what to compare
Recheck the calibration after changing the sensor, fixture, mounting, contact geometry, or operating temperature, and when you observe a baseline change. The sources do not establish a universal recalibration interval; choose one based on the application’s stability needs and observed behavior.
There is no universal calibration curve or acceptance threshold established for all stretchable pressure sensors. The FlexiForce manual describes a specific sensor family, and the 2017 study evaluates flexible force sensors in the context of compression-therapy monitoring. A recent reliability review also identifies inconsistent reporting of drift, hysteresis, and environmental test conditions as a limitation across the field. Review of reliability considerations for flexible pressure sensors.
When comparing sensors or calibration methods, compare the conditions that affect readings, not just a headline accuracy number:
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Quick Recap
- Usable force or pressure range and whether your application stays within it.
- Loading geometry, contact footprint, mounting, and curvature.
- Temperature and humidity conditions used for calibration and testing.
- Differences between loading and unloading, repeatability across cycles, and drift over the expected measurement duration.
- Calibration residuals or verified error against reference loads across the range.
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