17-4PH Stainless Steel
Standard material common in hydraulic and pneumatic applications known for its high yield strength
Semi-Custom and Custom Pressure Sensors
While Core Sensors offer a complete portfolio of standard configurations of pressure sensors, transducers, and transmitters, some applications require a semi-custom or custom pressure transducer. By combining various mechanical, electrical, and material customizations, Core Sensors can manufacture custom pressure measurement solutions for most applications measuring liquids or gases.
Custom Sensor Materials
Core Sensors offers one of the most diverse sensor material portfolios in the pressure sensor industry. By customizing the sensor material, systems can measure the pressure of corrosive liquids and gases in various environments. Using bulk silicon MEMS technology, Core can apply its silicon strain gages directly to a variety of metal materials.
High pressure transducer with customized thread to operate up to 4500 bar
CS90 downhole sensor with welded process connection lip
Custom vented downhole pressure sensor housing for submersion in non-conductive fluid
Custom differential pressure transducer with process connections on the bottom of the housing and anodized aluminum housing option
Panel mountable pressure sensing element eliminates bulkhead fittings (also available with 1/8" NPT female threads)
Custom compact pressure temperature sensor
Pressure sensor example of a shortened housing to accommodate space constraint
Custom Sensor Mechanical Interface and Housing
After the material is selected, it’s important to understand the mechanical interface in which the sensor is installed. Whether retrofitting an old system or sensor design or designing new equipment, customers face challenges with the availability of the right sensor mechanical interface. At Core Sensors, we combine sensor material with a variety of standard threaded connections to offer very competitive lead times. But, we also create customized interfaces that match the application and pressure rating requirements.
- Custom threads – from standard commercial threads to customized designs with integral or independent metal-to-metal seals
- Welded Installations – for high pressure or purity applications
- O-ring seal interface – for mid-to-high volume, minimal sensor volume, or low-profile applications
When designing a custom pressure sensor interface, tooling may be required to enable the test and calibration of the sensor. Core Sensors will be a partner in the design process to accommodate the application and manufacturing process, keeping you on-time and budget friendly.
Similarly, the housing of the pressure sensor can be customized to customer requirements. Our engineers will partner with you to design a custom pressure sensor or custom differential pressure sensor that fits within space constraints or matches the overall size requirements within our mechanical limitations. Additionally, the sensor can be designed with a specialized housing material to match the sensor or a different material such as anodized aluminum to survive in a harsh environment or reduce weight.
Custom Pressure Transducer Output Signal
Like the mechanical interface, many customers come to Core when a customized output signal is required to retrofit an existing transducer or develop a new product. This includes millivolt, voltage, and current output pressure sensors. Our sensor technologies produce a high amount of raw signal and are combined with the latest ASIC technologies and proprietary sensor calibration. This combines for design flexibility to match the application requirements.
Factors such as current consumption, available supply voltage and transmission distance can alter the options, but Core Sensors will partner to find a solution.
Pressure transducers can be calibrated for various pressure types and ranges, including:
Pressure sensors can be designed with a custom electrical connection to simplify installation or increase quality through Poke Yoke.
- Inline Connector – ensure the proper fit and reduce mating harness cost. Keeps soldering and crimping with our experts and is 100% inspected before shipment. Over-molded designs available.
- Custom Cable Length or Material – design the right cable length and material depending on factors such as UV exposure or submersion in corrosive liquids. Add protection such as cable armor over the jacket.
- Custom Connector – interface with the connector you need directly at the sensor
- High Temperature Exposure – custom glass-to-metal seal interfaces, jacketed cables, and wires available over 200°C
Custom pressure sensors enable customers to get closer to an ideal state of integration within a system. Partner with a company that understands pressure sensors and applications. Moreover, the team is responsive and always willing to pick up the phone to work through a challenge. Contact Core Sensors to design a custom pressure sensor or transducer for your application — from corrosive chemical environments to confined spaces.
Frequently Asked Questions
Is there a minimum order quantity for custom pressure sensors?
A minimum order quantity (MOQ) is commonly required for a custom pressure sensor or transducer. This depends on the level of complexity, existing tooling, and overall type of customization. For example, a custom machined thread will require customized manifolds and/or adapter to test and calibrate the pressure transducers in our chambers. The quantity, short term and long term, will influence the cost factor.
How long does it take to develop and manufacture a custom pressure transducer?
Developing a custom pressure transducer is also dependent on the level of customization. For a simple sensor with inline connector, the timing can be weeks. Custom mechanical or material changes can be closer to a few months. We’ve experienced End of Life on competitor product lines that created a high level of urgency to design and manufacture solutions. Expedites are possible with most customizations, so please contact us to discuss.
Do you require Non-Disclosure Agreements (NDA’s)?
NDA’s are commonly requested in reference to custom products. Core Sensors has a standard non-disclosure agreement or can review a customer’s NDA.
Do you offer private labeling?
Private labeling refers to marking products with customer-specific information on the product. We recognize this can protect proprietary design characteristics and aide future service on the sensor. We offer custom labeling and laser etching for our products for OEM applications.
Which materials are best for corrosive liquids and gases? How do I choose between 17-4 PH stainless steel, 316L stainless steel, Hastelloy, Inconel, or Titanium?
For more information on how to choose the right pressure sensor material, visit: Pressure Sensor Material Options
This offers a material breakdown between the options listed above.
What is the difference between absolute, compound, bi-directional, and zero-offset pressure transducers?
| Pressure Type | Definition | Reference Point |
| Absolute Pressure | Pressure measured relative to a perfect vacuum. | Vacuum 0 pressure) |
| Barometric Pressure | Subset of absolute pressure measurement; measures barometric pressure / altitude with reference to vacuum. | Vacuum (0 pressure); calibrated with offset such as 1100 mbar to 1700 mbar absolute |
| Bi-directional | Pressure measured relative to a perfect atmosphere with a calibrated signal measuring equal parts vacuum and positive pressure (- 5 to +5 PSIG. | Atmospheric pressure (14.7 PSI at sea level) with negative pressure zero offset equal to the positive full scale pressure |
| Compound Pressure | Both positive and negative pressures relative to atmospheric pressure; common in compressor applications. | Atmospheric pressure (14.7 PSI at sea level) |
| Compound Sealed Gauge | Positive and negative pressures relative to a sealed reference point; provides additional environmental protection. | Fixed reference (not atmospheric) |
| Zero Offset (Gauge) | Measures pressure relative to atmosphere but is calibrated to have a fixed “0” pressure reading above or below zero. | Atmospheric pressure (14.7 PSI at sea level) with positive or negative zero offset |
Can Core Sensors retrofit or replicate an existing legacy transducer design?
Yes, this is common. Competitors will often obsolete products with little to no notice and last-minute one-time buys. Core will work to both retrofit the design and make design enhancements where possible. This can include legacy millivolt pressure sensors as well as amplified and hazardous area products. In many cases, customization is not required and can be accomplished within the standard catalog.
What are the advantages of using differential pressure transducers?
Differential pressure transducers offer several advantages, including:
- High accuracy and stability.
- Independence from atmospheric pressure changes.
- Suitability for various applications such as flow, level, and filter monitoring.
- Ability to perform well in applications susceptible to over-pressurization
Is it possible to customize a hazardous location approved pressure transducer?
Short term, we cannot customize a standard product approved for hazardous locations. Our products are certified to certain documentation and standards that cannot be altered. That said, we partner with customers to both add product certifications to our portfolio as well as add to our existing hazardous location files. This is reserved for applications that understand the time commitment to partner with our approval agencies to test and process additions. Also, customers can certify a design within there systems in certain applications such as NSF ratings.
Are custom differential pressure transducers available?
For OEM applications, Core can customize our differential sensor platform to meet your needs. From process connections and electrical connections to materials and outputs, Core will partner with you to design and manufacture the right product. Note that for hazardous area rated products, the level of customization can be extended based on additional testing requirements and resubmission to approval agencies.
Connect With Our Sales Team
We are ready to help! Fill out the form and a member of our sales team will contact you to discuss your custom sensor design and requirements. You can also give us a call at (862) 245-2673.
