Custom Force Sensors Tailored for your application
Need to measure force in a machine, device, tool or test setup?
HITEC Sensors designs custom force sensors for applications where standard sensors cannot meet the load case, space, output or environmental requirements.
Our custom strain gauge force sensors measure tension, compression, contact force and actuation force. They support static and dynamic force measurement in demanding systems.
HITEC force transducers are used in aerospace, medical, robotics, automotive, industrial, energy and test applications.
Force Measurement Where It Matters
Force is not always easy to measure.
The available space may be tight. The load path may be complex. The sensor may need to fit inside a tool, fixture, actuator, structure or OEM product.
A standard force sensor may not solve that problem.
HITEC designs the sensor around the application. We review the load direction, mechanical interface, mounting points, output needs and operating environment.
The result is a force sensor that fits your system and captures useful data.
Custom Built Sensors For Your Load Case, Interface and Output
Custom force transducer design starts with the application.
HITEC can customize:
- Tension force measurement
- Compression force measurement
- Bidirectional force measurement
- Contact force measurement
- Actuation force measurement
- Static or dynamic loading
- Load range and overload capacity
- Sensor size and shape
- Mounting holes, threads, flanges and adapters
- Load buttons, rods, pins, links, beams or embedded features
- Materials and surface protection
- Cable exit, connector and strain relief
- Electrical output and signal conditioning
- Integrated or in-line electronics
- Wireless, digital or telemetry output options
- Calibration method and documentation
- OEM production requirements
HITEC’s existing force sensor and electronics page notes that available output options include CAN, current, Bluetooth, digital, frequency, telemetry, voltage and wireless. HITEC can also design custom circuit boards and flexible PCBs in house for space-limited applications.
The Benefits of Custom Force Sensors
A standard force sensor is the right choice when the catalog part fits.
A custom force sensor is the better choice when the measurement task is tied to the product design.
Custom force sensors help when you need to:
Place force measurement inside a machine, device, tool, fixture or compact assembly.
Capture force where it occurs, not where a standard sensor can be mounted.
Avoid added brackets, adapters or fixture changes that affect the measurement.
Tune the sensor geometry, range and sensitivity to the actual force window.
Build measurement into devices, tools, machines or production platforms.
Design for actuation, impact, fatigue, vibration or repeated loading.
Engineer for temperature, moisture, shock, corrosion, washdown, vacuum or long duty cycles.
From Concept to Validated Solution
We follow a structured development process to ensure performance, reliability, and repeatability.
Custom force sensor types
Custom Tension Sensors
Measure pulling force in rods, links, cables, actuators and structural members.
Common uses: actuator testing, cable tension, lifting systems, linkages and product validation.
Custom Compression Sensors
Measure pushing force, press force, contact force or clamping force.
Common uses: assembly systems, presses, fixtures, medical devices and production equipment.
Custom Bidirectional Force Sensors
Measure tension and compression in the same sensor.
Common uses: actuator tests, robotics, fatigue rigs, control systems and dynamic load measurement.
Custom Contact Force Sensors
Measure force at a contact surface or interaction point.
Common uses: surgical tools, robotic grippers, touch interfaces, clamping systems and product testing.
Custom Actuator Force Sensors
Measure force through electric, hydraulic or pneumatic actuators.
Common uses: aerospace mechanisms, industrial machinery, robotics, test stands and motion control.
Custom Link and Rod-End Force Sensors
Measure force through a link, rod end or inline connection.
Common uses: control linkages, suspension systems, structural tests, cranes and heavy equipment.
Embedded OEM Force Sensors
Build force sensing directly into a customer product or assembly.
Common uses: medical devices, power tools, robotics, industrial machines and safety systems.
Custom Force Transducers with Electronics
Combine force measurement with signal conditioning or digital output.
Common uses: compact devices, automated systems, data acquisition platforms and OEM products.
Standard or Custom Sensors
Which is better for strain gauge sensing?
Design starting point
| Standard Sensor | Custom Strain Gauge Sensor |
|---|---|
| Selected from an existing catalog range. Best when the application matches a known form factor and capacity. | Engineered from the measurement problem outward. The sensor is designed around the structure, load path, interface and performance target. |
Mechanical envelope
| Standard Sensor | Custom Strain Gauge Sensor |
|---|---|
| Fixed body size, mounting pattern, connector position and cable exit. May require fixture changes or added adapters. | Built around the available space. Geometry, mounting features, lead exits and connector location can be matched to the assembly. |
Load path
| Standard Sensor | Custom Strain Gauge Sensor |
|---|---|
| Works best when force, torque or moment is introduced in a clean, predictable way. Off-axis loads may reduce measurement quality. | Designed around the real load path. The sensing element can account for side loads, bending, torque, thrust, clamping force or multi-axis loading. |
Capacity and resolution
| Standard Sensor | Custom Strain Gauge Sensor |
|---|---|
| Limited to standard ranges. The selected sensor may be oversized or undersized for the required measurement window. | Capacity, sensitivity and overload protection can be tuned to the application. This helps improve usable signal and protects the sensor in service. |
Mounting and interfaces
| Standard Sensor | Custom Strain Gauge Sensor |
|---|---|
| Uses standard threads, holes, flanges or adapters. Integration may shift the measurement point. | Interfaces can match the customer part. This can include bolt patterns, pins, shafts, clevises, flanges, sockets, washers or embedded features. |
Accuracy in the actual system
| Standard Sensor | Custom Strain Gauge Sensor |
|---|---|
| Accuracy is usually based on catalog test conditions. Final performance depends on installation, fixtures and load introduction. | Performance can be validated against the real installation. Calibration can account for the fixture, load direction and operating conditions. |
Dynamic performance
| Standard Sensor | Custom Strain Gauge Sensor |
|---|---|
| Stiffness, deflection, frequency response and fatigue life are fixed by the standard design. | Stiffness, deflection, natural frequency, fatigue rating and duty cycle can be considered during design. |
Environmental fit
| Standard Sensor | Custom Strain Gauge Sensor |
|---|---|
| Limited to available material, sealing, temperature and cable options. Extra protection may require external packaging. | Materials, sealing, coatings, cable protection and temperature compensation can be selected for the environment. Useful for washdown, vacuum, high temperature, subsea, medical, aerospace or high-vibration use. |
Electrical integration
| Standard Sensor | Custom Strain Gauge Sensor |
|---|---|
| Standard bridge output, connector, cable length or signal format. May require external conditioning or wiring changes. | Output, bridge configuration, connector, cable routing, signal conditioning, wireless connection, TEDS and electronics can be matched to the system. |
Calibration strategy
| Standard Sensor | Custom Strain Gauge Sensor |
|---|---|
| Factory calibration is based on standard loading conditions. System-level effects may remain outside the certificate. | Calibration can be built around the measurement task. Options may include multi-point, multi-axis, torque, compression, tension, system-level, temperature or application-specific calibration. |
Manufacturing readiness
| Standard Sensor | Custom Strain Gauge Sensor |
|---|---|
| Fastest route when the catalog part fits. Lower upfront engineering effort. | Better suited for OEM production or critical test systems. Design reviews, prototyping, DFM and repeatable production can be built into the program. |
Lifecycle risk
| Standard Sensor | Custom Strain Gauge Sensor |
|---|---|
| Lower upfront cost, but adapters, rework or compromised data can add cost later. | Higher upfront engineering effort, but can reduce integration risk, redesign loops and long-term measurement uncertainty. |
Best fit
| Standard Sensor | Custom Strain Gauge Sensor |
|---|---|
| Use when size, range, mounting, output, environment and calibration needs are already covered by a standard product. | Use when the sensor must fit the machine, not the other way around. Best for constrained spaces, unusual load paths, harsh environments, OEM integration and high-value data. |
Not sure whether you need standard or custom?
Send us your load case, space limits, environment and output requirements. HITEC will help determine whether a standard sensor fits or a custom strain gauge sensor is the better path.
Applications for Custom Force Sensors
Measure force in actuators, control linkages, landing gear systems, structural tests, propulsion systems and flight hardware.
Custom force sensors can be built for tight spaces, harsh environments and qualification-driven programs.
Measure gripping force, insertion force, press force, actuator force and end-effector loads.
Custom force sensors support force feedback and process control.
Add force measurement to surgical tools, robotic surgery systems, infusion systems, patient handling equipment, rehabilitation devices and diagnostic systems.
Compact designs can support sensitive measurement in small devices.
Measure loads in braking systems, steering systems, suspension components, EV platforms, crash rigs, durability tests and production validation equipment.
Monitor force in presses, clamps, fixtures, conveyors, actuators, packaging systems and heavy machinery.
Custom force sensors can be designed for production environments.
Support force measurement in oil and gas equipment, renewable energy systems, power generation equipment, winches and field monitoring systems.
Materials and sealing can be selected for the operating environment.
Speak to our experts
Provide us with your information and our team will contact you
Discover HITEC's Custom Sensor Capabilities
Match load paths with custom tension, compression and overload measurement.
Fit force measurement into constrained spaces without sacrificing signal integrity.
Measure rotating and reaction torque across shafts, flanges and drivetrains.
Resolve force, torque and moment vectors across complex load paths.
Replace structural pins with load sensing while preserving joint geometry.
Measure tension and compression loads through custom engineered force transducers.