Under pressure: how we design a pressure mapping insert
The world harnesses pressure in all kinds of ways – from typing on a keyboard and drinking with a straw, to designing brakes on cars, and flying an aeroplane. But the possibilities of what we can do with pressure when it’s mapped effectively are expanding rapidly. It’s quickly becoming a competitive advantage for businesses in a number of sectors.
In healthcare, for example, mapping pressure will help prevent pressure sores, monitor rehabilitation progress, and personalise care. In sport and fitness, equipment with pressure mapping built in will be able to evaluate performance and provide personalised feedback to professional and amateur athletes alike. And in automotive, pressure mapped seats will take the driver experience to the next level without the need for cameras or other sensors.
At TG0, we’re working hard to bring the next generation of pressure mapping to our client’s projects, products and hardware, at a price that suits their requirements and budget. Here’s what that process looks like in practice:
- Define the sensing area
Our designers start every project by determining the size and scope of the sensing area. This will involve user testing, client input, and an in-depth technical analysis of the product to determine the number of sensors required, based on the use case or goal our client is trying to achieve. A car seat, for example, may require different sensing inserts in the seat pan, backrest, and bolsters. Whereas a shoe insole will need a much smaller sensing area.
- Determine the insert location
Once the sensing area is defined, we identify the best location for the sensing insert itself. Typically, this can be incorporated within a product’s existing structure and manufacturing processes – in a car seat, for example, the sensing insert could replace an existing layer of foam. Our expertise means we can identify the optimum depth for each type of product, weighing up factors such as performance and comfort.
- Select the appropriate material
Once the location is finalised, we will choose a suitable conductive material – whether hard or soft, foam or sheet – to meet specific needs for hardness, thickness, and stretchability. We also combine the sensing element with appropriate non-conductive aspect materials to integrate it into the product’s existing surface. We perform in-house material testing and collaborate with external labs to meet various certifications, such as stretching, folding, waterproofing, and extreme temperature storage tests. Our unique ability to use conductive material rather than rely on electronic components means we’re able to make considerable cost savings at this stage.
- Set the resolution
Finding the optimal resolution for the pressure mapping insert requires a balance to be found between cost and usability. The resolution needs will vary by project, with higher XY resolution requiring more MCU processing power, and increasing costs and assembly challenges. The right resolution will depend on how much force will typically be applied to the pressure sensing area, and how much data/information is required.
- Consider mechanical design
After finalising the sensor design, we also develop mechanical solutions to integrate components like cables, printed circuit boards (PCBs), structure parts and connections seamlessly into the product, to ensure the signal can be read with software designed by TG0, or the client themselves.
- Time to calibrate
Once the hardware is in place, it’s necessary to ensure the raw data is mapped to the pressure force information. We have established calibration methods and stations that accurately and reliably convert the sensor’s output into meaningful force or pressure data tailored to the device’s specific needs.
- Taking a design to manufacturing
Once the design is complete, we move forward towards manufacturing the insert, collaborating with our manufacturing partners or the client’s existing suppliers to bring the design into mass production.
More customised, more reasonably priced
The opportunities around pressure mapping are still evolving. But TG0 offers an end-to-end solution that is lower priced, customised to fit into existing products (where relevant), and doesn’t require cameras or other sensors. Technologies such as machine learning and artificial intelligence will allow us to continue innovating new possibilities in the future, capturing more data and visualising relevant insights over a very short timeframe. It’s an exciting prospect, and one that starts with taking the right approach to pressure mapping.
