Fibos Sensor specializes in high-quality custom load cell design and OEM/ODM production. We customize solutions based on size, capacity, output, and mechanical fittings, making our Customized Load Cell ideal for medical devices, robotics, and industrial automation where standard units fall short. As a reputable Customized Load Cell Manufacturer, we prioritize precision, dependability, and quick response to customer specifications, resulting in seamless integration into complex systems and production lines.
Precision tailored to application: A Customized Load Cell Manufacturer like Fibos can engineer sensors to match exact force ranges, resolutions, and linearity requirements, delivering improved measurement fidelity compared to off-the-shelf options.
Optimized form factor: By adjusting dimensions, mounting interfaces, and electrical connections, we reduce system integration risk and optimize space utilization in compact equipment or constrained environments.
Enhanced reliability in demanding environments: Custom coatings, seals, and materials chosen for specific humidity, temperature, and chemical exposure improve durability and lifecycle cost.
Reduced system-level costs: Fewer adapters, fewer calibration steps, and tighter tolerances translate to lower assembly time, faster time-to-market, and improved overall system performance.
Better traceability and compliance: Customized solutions enable traceable materials, documented manufacturing processes, and documentation aligned with industry standards, which is critical for medical, aerospace, and food equipment.
OEM/ODM value proposition: Partnering with a Customized Load Cell Manufacturer allows customers to co-create products, safeguarding intellectual property, and ensuring long-term supplier support for production ramps and after-sales service.
Characteristics: Longitudinal force measurement with compact footprint, designed for tight installation spaces, high-stiffness applications, and high-cycle environments.
Benefits: High rigidity, excellent repeatability, and reduced hysteresis ideal for continuous tension monitoring in web handling, rolling mills, and conveyor systems.
Characteristics: Through-bolt or flange-mounted design for straightforward integration into load-bearing joints and structural assemblies.
Benefits: Quick installation, robust preload stability, and compatibility with modular machinery, robotics grippers, and heavy-duty automation.
Characteristics: Integrated within bearing arrangements to monitor axial load without compromising bearing performance.
Benefits: Minimal footprint, real-time load data in rotating equipment, and reduced mechanical intrusion in compact systems such as servo axes and automated tooling.
As a leading Customized Load Cell Manufacturer, Fibos provides options across standard and nonstandard geometries, including multi-axis configurations, to suit complex load paths and measurement strategies.
Force sensing in infusion pumps, surgical robots, and rehabilitation devices.
Requirements: high accuracy, biocompatible materials, and validated calibration procedures.
Gripper force feedback, torque measurement, and tactile sensing in collaborative robots.
Requirements: fast response, low drift, and integration with control systems.
Tension sensing in extrusion, winding, and packaging lines; force monitoring in presses and forming machines.
Requirements: rugged build, environmental resistance, and long service life.
Load monitoring in testing rigs, structural testing, and flight instrumentation.
Requirements: traceability, high reliability, and compliance with aerospace standards.
NTE (No-Till Equipment) packaging lines, portion control, and dosing systems.
Requirements: food-grade materials, washdown resistance, and sanitized manufacturing processes.
Stainless steel, aluminum, nickel-based alloys, and advanced composites, selected for strength-to-weight, corrosion resistance, and load-path suitability.
Surface finishes include corrosion-resistant coatings, passivation, electro-polishing, or custom plating to match process environments.
Strain gauge rosettes, Wheatstone bridge configurations, and various output formats (mV/V, serial digital, CANopen, BUS protocols) to integrate with customer systems.
Integrated temperature compensation circuits, material selection for thermal stability, and compensation algorithms to maintain accuracy over wide temperature ranges.
Design options for 2D/3D force measurement, including yaw, pitch, and roll sensitivity management, enabling precise measurement in dynamic applications.
Multiple automated production lines, in-line testing, and rigorous QC to ensure consistency across high-volume runs.
Comprehensive inspection steps: material checks, laser marking, cleaning, curing, welding, and extensive product testing to uphold the highest standards.
Tailored labeling, traceability records, calibration certificates, and installation guides designed for fast integration and compliance.
Mechanical strength and fatigue life: Selecting alloys with favorable fatigue properties reduces sensor drift and improves lifespan under cyclic loads.
Corrosion resistance: For aggressive environments, stainless steel and protective coatings extend service life and reduce maintenance.
Thermal stability: Low-thermal-expansion materials minimize sensitivity to temperature fluctuations, preserving accuracy in critical applications.
Biocompatibility and cleanability: For medical and food-contact applications, material choices prioritize cleanability and compatibility with sterilization processes.
Define load range, sensitivity, nonlinearity, hysteresis targets, environmental conditions, mounting interfaces, electrical connectors, and communication protocols.
Evaluate form factors, lever arms, and mounting constraints; assess manufacturability and cost targets.
Finite element analysis (FEA) for stress distribution; tolerance analysis and thermal simulations to predict performance across operating envelopes.
Build prototypes, conduct static/dynamic tests, and validate against customer specifications; refine as needed.
Establish BOM, material certificates, calibration data, and documentation needed for quality systems (ISO, IEC, or sector-specific standards).
Ramp up manufacturing with pilot runs, process validation, and QA checklists to ensure consistent quality at volume.
Final performance verification, environmental testing (temperature, humidity, vibration), and customer approval.
Calibration services, replacement parts, and firmware or software updates to maintain system performance.
Tolerance and accuracy targets: Align sensor grade and calibration approach with system requirements.
Electrical integration: Ensure compatible signal conditioning, connector types, and wiring layouts.
Mounting and installation: Design to minimize thermal and mechanical stress concentrations.
Environmental exposure: Plan for cleaning, moisture, dust, chemicals, and washdown cycles.
Lifecycle and serviceability: assess ease of repair, recalibration frequency, and spare parts availability.
Robotic handling, automated welding, and precision assembly lines to ensure repeatability and throughput.
Rigorous testing at multiple stages to catch deviations early and ensure each unit meets performance specs.
Serialization and data logging for every unit, enabling full lifecycle visibility and easy root-cause analysis.
Traceable calibrations with documented results, supporting QA processes and customer compliance needs.
Co-design with engineering teams, with iterative prototyping and regular milestones.
Fibos acts as a turnkey supplier for specific product families with optimized supply chain and branding.
Customized Load Cell Manufacturer services with customer branding and documentation catered to market and regulatory needs.
Start from the maximum expected force with a comfortable margin for safety and dynamic peaks. Then specify required sensitivity to resolve the smallest meaningful change in force. Consider the measurement cycle, sampling rate, and control system resolution. Include environmental factors (temperature, humidity, chemical exposure) which influence material choice and compensation strategies. A formal requirements document should map targets to measurable metrics (range, sensitivity, nonlinearity, hysteresis, repeatability) to guide a Customized Load Cell Manufacturer in selecting or engineering a suitable solution. Fibos typically collaborates with customers to define these parameters during the discovery phase, ensuring the final sensor meets system performance with robust calibration.
Common mounting options include flange mounting, through-bole mounting, and integrated bearing arrangements, designed to match the host machine’s load path and assembly constraints. Specific options like Roll Tension Sensor, Flange Tension Sensor, and Compact Bearing Tension Sensor address different installation philosophies:
Roll Tension Sensor: long-span force measurement with compact footprint, ideal for web handling and high-cycle applications.
Flange Tension Sensor: flange- or through-bolt mounted for quick, stable preload and robust interface with modular machinery.
Compact Bearing Tension Sensor: integrated into bearing assemblies to minimize intrusion while delivering real-time axial load data.
These configurations can be further customized with tailored connectors, cable routing, and protective enclosures to fit specialized environments.
Yes. Multi-axis load sensing is supported to capture 2D/3D force vectors and their coupling effects (including yaw, pitch, and roll). Implementing multi-axis sensing requires careful mechanical design to minimize cross-axis interference, dedicated calibration strategies, and advanced signal processing to decouple axes. While multi-axis sensors enable richer data for complex applications (e.g., robotics, haptics, advanced manufacturing), they demand rigorous validation to maintain accuracy across operating envelopes. Fibos provides design options and testing protocols to ensure performance targets are met in real-world conditions.
Material choice should account for mechanical strength, fatigue life, corrosion resistance, and thermal stability. Common metallic options include stainless steel, aluminum alloys, and nickel-based alloys, chosen for strength-to-weight ratio and environmental compatibility. Surface treatments (e.g., coatings, passivation, electro-polishing, anodizing) extend life in corrosive or washdown environments and aid cleanability in medical or food-related contexts. For medical and food applications, biocompatibility and cleanability are essential. The final material and surface finish are selected to balance durability, regulatory requirements, and total cost of ownership.
Temperature changes can cause expansion, material property shifts, and bridge resistance drift, impacting accuracy. Compensation strategies include using temperature-stable materials, dedicated temperature sensors, and active or passive compensation algorithms in signal conditioning. Some designs implement temperature compensation within the sensor bridge or in the accompanying electronics to maintain performance across a wide operating range. Calibration at multiple temperatures is often performed to establish reliable correction curves for traceable performance.
Lead times vary by project scope, complexity, and production readiness. Typical phases include requirements definition, conceptual design, detailed design and simulation, prototyping, testing, qualification, and production transfer. Early engagement and clear specifications help shorten development cycles, while maintaining rigorous quality controls. With scalable automation and inline testing, manufacturers can accelerate volume production once the design is validated. For precisely scoped projects, a defined project plan with milestones and QA gates is standard practice.
Comprehensive documentation is standard, including:
Material certificates and BOM for traceability.
Calibration certificates with traceability to national or international standards.
Mechanical drawings, installation templates, and electrical connection diagrams.
Environmental and functional test reports, including acceptance criteria and results.
Quality system documentation aligned with ISO/IEC or sector-specific standards.
Firmware/software release notes if applicable.
These documents facilitate quality audits, regulatory compliance, and seamless integration into customer quality systems.
Integration approaches depend on the customer’s control system and protocol requirements. Typical outputs include analog mV/V, serial (RS-485/RS-232), and digital bus protocols such as CANopen, EtherCAT, Modbus, CAN, I2C, or SPI. The chosen interface is matched with appropriate signal conditioning and power supply, ensuring reliable data transmission, minimal latency, and robust noise immunity. Documentation should include electrical interfaces, wiring diagrams, and protocol handles to simplify system integration.
Durability in high-cycle settings benefits from materials with good fatigue properties, protective coatings, and sealed assemblies to resist contamination. Regular recalibration intervals, inspection of seals and connectors, and predictive maintenance planning help sustain measurement accuracy over time. A well-designed customized load cell can reduce maintenance requirements by minimizing wear points and ensuring stable electrical characteristics across cycles.
Regulatory compliance requires traceable materials, clean manufacturing environments, validated calibration procedures, and complete documentation packages. For medical devices, adherence to standards such as ISO 13485, ISO/IEC 17025 calibration, and relevant FDA or CE pathways is important. For food-contact applications, material biocompatibility, washdown compatibility, and sanitary design principles matter. A reliable Customized Load Cell Manufacturer will provide certificates, validation data, and risk assessments to support regulatory submissions and quality audits.
After-sales support typically includes recalibration services, repair and replacement part provisioning, firmware or software updates, and technical support for installation, integration, and field issues. Calibration services help maintain traceable performance over time, while spare parts programs reduce downtime in production environments. An established supplier should offer service level agreements (SLAs) and predictable lead times for sensitive industrial applications.
Deep engineering expertise across force measurement and mechanical design.
Robust QA processes ensuring repeatable performance across batches.
Flexible manufacturing capabilities to scale from prototyping to mass production.
Global support network and rapid response for design changes, calibration needs, and after-sales service.
Commitment to innovation, with ongoing R&D into sensor materials, signal conditioning, and data analytics. Contact us for your needs.
