Enhancing Part-to-Part Repeatability of Force-Sensing Resistors Using a Lean Six Sigma Approach

Polymer nanocomposites have found wide acceptance in research applications as pressure sensors under the designation of force-sensing resistors (FSRs). However, given the random dispersion of conductive nanoparticles in the polymer matrix, the sensitivity of FSRs notably differs from one specimen to another; this condition has precluded the use of FSRs in industrial applications that require large part-to-part repeatability. Six Sigma methodology provides a standard framework to reduce the process variability regarding a critical variable. The Six Sigma core is the DMAIC cycle (Define, Measure, Analyze, Improve, and Control). In this study, we have deployed the DMAIC cycle to reduce the process variability of sensor sensitivity, where sensitivity was defined by the rate of change in the output voltage in response to the applied force. It was found that sensor sensitivity could be trimmed by changing their input (driving) voltage. The whole process comprised: characterization of FSR sensitivity, followed by physical modeling that let us identify the underlying physics of FSR variability, and ultimately, a mechanism to reduce it; this process let us enhance the sensors’ part-to-part repeatability from an industrial standpoint. Two mechanisms were explored to reduce the variability in FSR sensitivity. (i) It was found that the output voltage at null force can be used to discard noncompliant sensors that exhibit either too high or too low sensitivity; this observation is a novel contribution from this research. (ii) An alternative method was also proposed and validated that let us trim the sensitivity of FSRs by means of changing the input voltage. This study was carried out from 64 specimens of Interlink FSR402 sensors.