Thin-film Sensors Achieve Accurate Sensing at 950℃

International Journal of Extreme Manufacturing

Prof. Kaichen Xu, Prof. Haibo Xie, and his coworkers from Zhejiang University have developed a laser-based fabrication method for thin-film temperature sensors that can operate reliably across an exceptionally wide temperature range, from –50 °C to 950 °C, without needing complex protective layers.

The research, published in the International Journal of Extreme Manufacturing , describes how a carefully controlled laser pulse can directly "write" a temperature-sensing layer onto a surface while also forming a protective coating at the same time. The technique could help monitor the health and safety of high-tech equipment used in aerospace, energy, and automotive industries.

The XU research group at ZJU is a highly interdisciplinary research group dedicated to the advanced manufacturing of flexible and conformal electronics for wearable/implantable monitoring in regular or extreme environments. "Our research mainly includes the development of innovative fabrication techniques, multifunctional devices, as well as system-level applications. Based on the principle of laser and matter interactions, we focus on manufacturing of versatile devices mainly using hybrid (ultrafast) laser processing platforms, which are endowed with multitasking features," said Prof. Kaichen Xu, corresponding author of this paper.

Traditional high-temperature sensors are difficult to make. They usually involve several layers of materials, require long sintering times, and need extra coatings to protect against heat and oxidation. Their laser method does all of that in one step.

The laser works by briefly heating the material, causing it to crystallize into a form that can conduct electricity and respond to temperature changes. At the same time, it creates a glass-like surface layer that protects the sensor from oxidation without adding extra materials or steps.

The result is a sensor that can track temperature in real time across a very wide range, with high accuracy and long-term stability. In lab tests, the sensors showed minimal signal drift (just 1.2%) even after 20 hours at high temperatures.

Because the process is fast and requires fewer materials and manufacturing steps, it could make it easier and cheaper to build sensors directly into parts like engine casings or gas pipelines, helping engineers spot early signs of wear, overheating, or failure.

The team is now working on expanding the technique to measure other things—like pressure, strain, and heat flow—on the same thin-film platform. Their long-term goal is to build smart sensor systems that can survive and work reliably in some of the toughest environments on Earth and beyond.


International Journal of Extreme Manufacturing (IJEM, IF: 21.3) is dedicated to publishing the best advanced manufacturing research with extreme dimensions to address both the fundamental scientific challenges and significant engineering needs.

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