Sensors

I would think a "Silk Screening" method might do the job.

Technology is available for technology transfer for production. Write to me using my email at the web page.

I started in thick film in the 1970's. I have designed and manufactured thick film circuits and thick film heaters for many types of industries. The design must be customized to the specific shape of the substrate. The printing composition and the design must be able to handle the watts/ sq. in. derated about 20% to 25% of the ink manufacturers spec. Thermoplastic, thermoset, or cermet inks are the typical resistive inks. The higher the wattage the more the cost per gram. Substrate selection is very important. Flexible substrates can be used with the polymer inks ranging from polyester to kapton (polyimide). A variety of fiber and molded plastic substrates can be used, as well. The material set I see being used for gas sensors is ceramic (96% alumina) as the substrate, cermet resistive ink, and a cermet solderable conductor for termination. Stainless steel with special dielectric for isolation can also be used for the substrate.

Contact A.M.I. in New Jersey for your printer, and B.T.U. for the thick film furnace. Now, there is such a technology called pen printing which deposits the heater track on non flat surfaces which might be appropriate for your application. If precise wattages are needed, the circuit or heater can be designed so the resistors are laser trimmed to +/-2%. I do not think this would be a requirement for your purposes.

I hope I have been assistance. Feel free to contact. -dkompara@drivesol.com