Advancing thin-film materials processing for flexible sensor fabrication

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The collaboration between the University of Waterloo and Forcen aims to develop scalable, flexible force-sensing films using advanced thin-film fabrication methods. Conventionally manufactured force sensing films, including those developed by Forcen, enable the increasing adoption of smart robotics in the medical, aerospace, and manufacturing industries. However, with increasing demand for custom sensors and rapid sensor deployment, a digital manufacturing methodology is required. Research into metal and polymer thin-film deposition, thin-film patterning, and thermal treatment of thin-film layers looks to advance the processing of thin-film materials to allow for faster transition between custom sensor design and final product. The aim of this research is to further our understanding of the relationship between thin-film processing techniques, and both surface chemistry and surface physics. The bonding of metals and polymers involves complex mechanisms that depend on surface functional groups and their interaction with metal oxides, which can be altered - both intentionally and unintentionally - during processing. Additionally, we aim to expand our understanding of the surface chemistry's influence on physical interactions that occur at thin-film interfaces during processing. Advances in these areas will not only significantly reduce manufacturing times, but also improve sensor shielding, thermal stability, and environmental resistance. The outcome of this project will place a Canadian company - Forcen - at the forefront of smart industrial robotics with integrated force-sensing technologies, and place a Canadian university - the University of Waterloo - at the forefront of thin-film sensor research.