Stainless Steel Laser Welded Gas Flow Sensors Assembly Probe

Sensor Device Components

A sensor is a device that detects physical phenomena – such as heat, light, sound, pressure, or motion – and produces an output signal in response. The sensor therefore acts as the “eyes and ears” of various systems by providing real-time data on its surrounding environment or machinery. At JACO Machine Works, our state-of-the-art CNC machines and Laser Welding services make us a top choice for manufacturing sensor components across various industries, including medical devices and aerospace components.

Sensors of All Types, for Any Industry

A sensor – also known as a measuring element or transducer – detects specific measurements and converts them into output signals. A typical sensor consists of three main components:

Sensitive Element: The part of the sensor that detects the measurement (e.g., light, heat, pressure).
Conversion Element: Converts the detected signal into an output.
Basic Conversion Circuit: Processes and transfers the data.

Sensors are therefore often compared to the five human senses, drawing parallels between their functions and those of our sensory organs. Here’s how sensors are utilized across various industries:

Medical Devices – Sensors used in the Medical Device industry encompass all five of the human senses, and beyond. From sound-sensitive and photosensitive sensors (such as stethoscopes and X-Ray detectors) for monitoring hearing and vision, to chemical and pressure-sensitive sensors (such as glucose monitors and blood pressure sensors) monitoring taste, smell and touch. Additionally, Micro Load Cell Sensors and Force Sensors are used for precise measurements in medical equipment.

Aerospace – Sensors are used in the Aerospace industry to monitor a wide range of physical and environmental activities. From air sensors that can detect smoke, fumes or leaks inside of an aircraft, to physics-based sensors monitoring parameters like airspeed and altitude. Meanwhile Pressure Sensors and Flow Sensors for gas and liquid are critical for maintaining safe and efficient operations.

Robotics – Robotic sensors mimic human senses for navigation, obstacle detection, and interaction. They include vision sensors (cameras), touch sensors (force-sensitive resistors), and proximity sensors (ultrasonic or infrared). Ultrasonic Liquid Level sensors are also used to detect liquid levels in robotic systems.

Biotech Life Sciences - Biotech sensors leverage molecular recognition abilities (such as biosensors using enzymes or antibodies to detect specific molecules) while chemistry-based sensors are used for analyzing DNA, proteins, and other biological molecules. Pressure Sensors and Micro Load Cell Sensors also play a vital role in various biotech applications.

At JACO, we utilize our decades of CNC experience and robust Quality Management System to produce sensors of all types with exceptional precision and repeatable results. Our Design for Manufacturing experts will help you identify opportunities for manufacturing and production optimization to bring your sensors to market in the quickest amount of time and at the lowest cost possible.

Customer Success Story

JACO was approached by a company specializing in gas mass flow measurement sensors for natural gas and hydrogen. They needed a probe comprising of a window housing and two sets of hypo tubes and plugs that were laser welded together. The critical aspect was achieving a hermetic seal on all welds to prevent the sensor shorting during operations - something that could lead to a catastrophic natural gas or hydrogen explosion. Additionally, the window component had to feature thin and consistent sidewalls for accurate flow measurement, along with precise hole locations for laser welding the hypo tubes.

Thanks to the precision and versatility of JACO’s 5-Axis Chiron FZ12MT machine, we successfully fabricated the intricate window component in a single machine cycle. The machine’s bar-fed automation allowed for unattended operation, significantly enhancing efficiency and reducing costs for our client. Furthermore, our Design for Manufacturing experts proposed a modification to the plug component’s design, ensuring a more consistent fit into the tube. As a result, laser welding became quicker, and leak test failures were virtually eliminated.

Machining and Laser Welding Services at JACO

5-Axis Precision Machining: 5-axis machining allows simultaneous movement in five different axes, enabling the creation of intricate shapes and contours. This flexibility ensures precise fabrication for intricate sensor components with complex geometry while maintaining tight tolerances.

Vertical and Horizontal CNC Milling: Our Vertical and Horizontal milling machines are versatile tools for producing components for sensor devices of all types. We use computer numerical control (CNC) to precisely remove material from a workpiece, resulting in accurate shapes and dimensions.

CNC Swiss Screw Machining: Our CNC Screw machines offer exceptional precision, efficiency, and repeatability. Their streamlined processes allow for reduced set-up times and therefore quicker production cycles, while their ability to handle various materials – from metals to advanced plastics and other exotic alloys – widens their scope to a broad range of sensor applications for any industry.

Laser Welding: Laser welding ensures airtight, hermetic seals between components. Whether in medical devices or aerospace applications, hermetic seals prevent moisture, dust, and other environmental elements from compromising critical sensor components. Meanwhile minimal heat-affected zones and precise fusion maintain the integrity of the sensor device.

Quality Assurance

JACO Machine Works’ comprehensive Quality Management System (QMS) is certified to ISO9001:2015 and AS9100D standards and complies with the requirements of ISO13485:2003. This certification underscores our commitment to safety, reliability, and precision in every component we produce. Whether it’s risk analysis, raw material inspection, recordkeeping, supplier management, or final assembly, we adhere to strict quality control measures. Here’s how our QMS ensures reliable and repeatable results:

Continuous Improvement: We evaluate process effectiveness continually. Factors like on-time deliveries, customer satisfaction, and quality conformance drive our improvement efforts.
Risk Analysis: Identifying and mitigating risks preemptively is essential. Our upper management reviews high-risk jobs before production begins, ensuring quality from the outset.
Traceability and Documentation: We maintain full lot and material traceability throughout production, complying with customer and regulatory specifications. Rigorous documentation ensures complete accountability and demonstrates product conformance.
State-of-the-Art Inspection: Our automatic CMM (Coordinate Measuring Machine) uses powerful software to inspect complex part geometries directly from solid model files. This technology allows for fast, repetitive inspections at a low cost.

Why Choose JACO?

JACO Machine Works is a leading CNC machining manufacturer of precision components for many industries, including medical device components, aerospace parts, components for electrical connectors and semiconductor equipment, robotic components, and more. Whatever your application might be, our engineers at JACO are happy to help bring your product to market in the shortest amount of time and at the lowest cost possible. We are committed to providing you with quality engineering, design services, and supply chain management that will exceed your expectations and meet every specification.