Pressure Mapping System

Sensor Products Inc. is a world leader in the niche field of tactile surface pressure and force sensors. There are following products available:

Analog Tactile Sensors:

These products consist of various film-like materials that reveal how pressure (or temperature in the case of Thermex) is disbursed between any two contacting and / or mating surfaces by virtue of a color change in the sensor material. This color change is instantaneous and captures a permanent archival high-resolution image of the pressure profile.


Surface Pressure Mapping Sensors

Unique, affordable & easy to use tool that reveals relative pressure distribution between two contacting, mating or impacting surfaces

Finding the relative pressure between your two contacting or impacting surfaces is affordable & easy with Pressurex-micro®. Since Pressurex® is a thin (20 mils) pressure indicating sensor film, it easily conforms to curved surfaces. You can even use the Pressurex® film in intolerant environments and tight places where conventional electronics transducers are useless.

All you need to do is to place the Pressurex® film between two contacting or impacting surfaces. After removal, the resulting image will show the relative amount of pressure applied as a grayscale pressure distribution profile. The greater the pressure, the darker the color intensity. Pressurex is perfect for any load less than 20 PSI (1.5 kg/cm²).

Pressurex® pressure film makes it even easier to analyze and interpret images when combined with our Topaq® imaging system.

An example of Pressurex-micro® Green in use

Grayscale pressure distribution profiles are rendered into clear, easy to interpret images within seconds. These images are a high resolution full-color representation of pressure distribution. Graphs and data accompany the view. This is the easiest and most effective way to determine pressure distribution between mating surfaces.

Common Applications


Composite Layups, Bolted Joints


Gasket Interfaces, Impacts, Fuel Cell Stacking, Clutches/Brakes, Tire Treads


Heat Sinks, LCD Bonding, PCB, Wafer Bonding, Wafer Polishing


Heat Sealing, Nip Impressions


Lamination Press, Injection Molding, Metal Stamping


Clamping, Biomechanics

Pressurex-micro® Green:

Pressurex-micro® Green reveals the pressure distribution between contacting or impacting surfaces.

How It Works

Simply place Pressurex-micro® Green pressure indicating sensor film between any two surfaces that touch, mate or impact. Apply pressure, remove the film and immediately the pressure distribution profile that occurred between the two surfaces is revealed. Pressurex-micro® Green is extremely thin (0.2 mm) and flexible, which enables it to conform to curved surfaces. It is ideal for invasive, intolerant environments and tight spaces not accessible by conventional electronic transducers.

An example of Pressurex-micro® Green in use






12 m x 27 cm

150 to 1,800 PSI - (11 to 127 kg/cm²)


12 m x 27 cm

150 to 1,800 PSI - (11 to 127 kg/cm²)




*Custom film types available upon request.


Operating Temperature

5°C - 35°C (41°F - 95°F) much higher for brief exposure

Humidity Range

10% to 90% RH

Gauge (Thickness)

0.2 mm - (8 mils)

Spatial Resolution

45 microns


± 17%

Shelf Life

2 Years

Thermex® Tactile Surface Temperature Indicating Materials

Thermex® is a unique temperature indicating material. As thin as a standard sheet of paper, Thermex® changes color to reveal relative temperature distribution between any two contacting surfaces. Upon exposure to temperature the Thermex® sheet instantaneously and permanently changes color. The intensity of that color is directly related to the temperature it was exposed to, allowing Thermex® to spot high or low temperature zones. Thermex® is inexpensive, precise and disposable.

Example of color enhanced image generated on Thermex® paper

Common Applications:

  • Form fill and seal machines
  • Ultrasonic welding
  • Lamination presses
  • Vacuum & Flat Web type machines


Temperature Range

200° F to 300° F (90° C to 149° C)


18 in x 13 in (45.7 cm x 30.5 cm)


2 mil (0.05 mm)

Normal Minimum Heat Seal Temperature

Low Density Polyethylene

245° F (118° C)

High Density Polyethylene

285° F (141° C)


350° F (177° C)

Ionomer (Surlyn)

220° F (104° C)

Ethylene Vinyl Acetate Copolymer (12%)

200° F (93° C)

Ethylene Vinyl Acetate Copolymer (18%)

170° F (77° C)

EZ-Nip® Impression Paper:

With any paper making and converting machinery, uneven nip rollers cause web handling waste and yield deficiencies. Non-uniform nips usually lead to wrinkles, web breaks and other troubles. For a system maintenance engineer, identifying these little problems with big consequences can be difficult and time consuming. EZ-Nip®, a thin color changing pressure activated paper, is an easy and efficient troubleshooting tool that can quickly be put to the task of detecting problem areas.

EZ-Nip® impression paper positioned in between nip rollers

EZ-Nip® determines the actual static nip width between two mating rolls. The paper immediately changes color upon the application of pressure, enabling the user to easily analyze/measure the nip "footprint" (nip width) both visually or, for more intense scrutiny, with a ruler or micrometer. This measurement then allows the technician to adjust roll pressures accordingly to achieve the proper nip alignment.

EZ-Nip® is an extremely economical and practical solution for determining proper crowns, roll parallelism and alignment, and symmetrical loading. EZ-Nip® is a self contained single sheet system making it useable by just one person, and can easily be encased for waterproofing purposes. EZ-Nip® is strictly designed for measuring nip width.



4 mils (0.1016 mm)

Humidity Range

10-90% RH

Pressure Minimum

350 PSI (70 kg/cm²)

Injection Mold-Align Tool

Of the hundreds of variables involved in injection molding, clamping mechanisms and platens often get less attention than they deserve. Good clamp performance is critical to minimize cycle times, optimize part quality, and maintain process consistency.

Mold-Align® is a unique, affordable and easy to use tool that reveals pressure distribution between mold platens.

Alignment and uniformity of the mold halves, platens, and clamping system is therefore critical. Whether an alignment problem stems from the mold parting line, the platens, or the clamping mechanism and tiebars, the results can be unnecessary machine wear, mold damage, broken tiebars, mold flash, and scrap parts.

Parting line aligned and uniform?

One way to ensure proper mating of the tool halves at the parting line is simply by having a level molding machine and parallel platens. Leveling a machine requires three machinist levels. If you have shorts and flash, you could have a mold or clamping alignment problem. This may not be the case if you are running a high-speed, thin-wall product-the problem may be simply not enough clamp force. To help establish whether flash stems from a mold or clamp alignment issue, check parting-line mating. In one typical check for uniform clamp pressure at the parting line, blueing agent

applied to one mold half will transfer to the other if there is contact at the parting line, but it will not distinguish between low or high touch force. More detailed information can be obtained with Mold-Align® paper, which changes color relative to the amount of contact force. Mold-Align® is an extremely economical and practical solution for determining proper mold alignment. Mold-Align® is a self contained (single sheet) paper that is quickly implemented, requires no training, and reveals a high resolution image of pressure distribution and void spots between mold plates.

Roll dimensions

10.5 in. x 50 ft. (26.7 cm x 15.2 m)

30.0 in. x 50 ft. (76.2 cm x 15.2 m)




Usable Humidity Range

10-90% RH

Pressure Range

1,000 - 6,000 PSI (70 - 422 kg/cm2)

Temperature Limit

200°F (93°C)

Electronic Real-Time Sensor Systems:

These systems reveal essentially the same information as the analog products, but in real-time and with more precision. Data is relayed back to a computer via cable interface or RF systems.

Sigma Nip:

Sigma-Nip® - an electronic nip analysis system, calculates and records nip width at multiple points across your rollers face length in real-time with unprecedented speed, accuracy and repeatability. The new Sigma-nip® system is not only more accurate, but can handle higher pressures than ever previously attainable.

Sigma-Nip® presents a revolution in quality control. Now, for the first time ever the technician is able to accurately, efficiently and economically measure roller profiles and alignment condition. Sigma-Nip® consists of a series of thin-film resistive ink pressure transducers on a carrier sheet. As this carrier sheet is loaded in between your rollers the Windows based software assimilates the readings into easily interpretable graphical images - all in real-time.

What Is Sigma-Nip®

Sigma-Nip® consists of a series of sensor elements that are placed in between two contacting rollers. Immediately upon closing of rolls, the sensor begins recording precise nip width measurements allowing you to instantaneously determine whether your rollers are aligned properly and are squeezing together sufficiently. Sigma-Nip® is a real-time system. What that means is that your roller adjustments can be made WHILE the sensor is actually in the closed (non-rotating) nip. This allows for unprecedented flexibility and speed.

Designed For Productivity

Sigma-Nip® comes complete with everything you need to quickly and accurately take nip impressions. Sigma-Nip® is designed with the intention of being used during routine maintenance or set up and is quickly disposed across the roller surface by just one person. The system is modular and portable and quickly interfaces to the USB port on any standard Windows laptop.

Why Use Sigma-Nip®

Proper roller alignment and pressure level are critical for both print clarity and web control. An evenly loaded roller set is much less likely to cause costly web breaks and sheet "walking", wrinkles, or fold-overs. Simply by virtue of routine tests, Sigma-Nip allows the user to greatly extend blanket life.


  • Quickly and accurately take nip impressions
  • Intuitive and user friendly Software
  • Modular and portable
  • Designed with the intention of being used during routine maintenance
  • Interfaces with any standard Windows computer through your USB port

Sigma-Nip® Technology

Through the application of sophisticated mathematical algorithms, Sigma-Nip® is able to discern the contact profile of the machine's cross direction with a higher degree of accuracy never before attainable. Each sensor is individually calibrated, serialized and carefully assembled to exacting tolerances. The sensor is designed to withstand repeated high pressures, conform to radiused surfaces and routine exposure to grease, liquids and inks.

System Specifications

Sensor Technology

Resistive Ink

Cycle Speed



± 6%


± 98%

Disk Space

200 MB

RAM Size

128 MB RAM


USB Port


Windows® 2000 / XP / Vista / 7

Sensor Specifications

Standard Sigma-Nip®

Mini Sigma-Nip®

Active Sensor Area

8.4 in (21.3 cm)

4.21 in (10.7 cm)

Usable Temp. Range

0 to 250°F (-17.7 to 121°C)

0 to 250°F (-17.7 to 121°C)


0.05 in (0.13 cm)

0.02 in (0.5 mm)

Nip Width Range

0.15 to 8.4 in (0.38 to 21.3 cm)

0.06 to 4.21 in (0.15 to 10.7 cm)

Min. Pressure

40 PSI (2.8 kg/cm2)

40 PSI (2.8 kg/cm2)

Max. Pressure

10,000 PSI (703 kg/cm2)

10,000 PSI (703 kg/cm2)

Max. Exposure Time

300 Sec

300 Sec

Sensing Points



Substrate Material



Tactilus® Real-Time Surface Pressure Mapping Technology:

What it does

Tactilus® allows the user to capture and record pressure conditions occurring in between any two contacting or impacting surfaces in real time. The paper-thin Tactilus® sensor is actually placed at the contact interface where it records and assimilates both pressure distribution and pressure magnitude on your Windows® based computer.

The innovation

Exciting advancements in conductive textiles have allowed us to develop a sensor that conforms better to your surface than ever before. Not only does the sensor conform better to curved surfaces but it stretches to alleviate shearing affects caused by shifting contact surfaces - an innovation that no other sensor company can touch! By biomimicking human skin we've taken surface contact pressure measurement to a whole new level.

Tactilus® now has all the electronics safely encapsulated on the sensor element itself. The Tactilus® sensor consists of a series of interlaced lines that create a matrix with as many as 16,384 unique sensing points. Tactilus® Windows® based software communicates with the sensor up to a theoretical 1,000 frames per second - fast enough for impact force measurement. For users desiring direct interfacing with their own control software Sensor Products can supply an API.

Industries we serve:


composite layup, fuel cell, lamination


BGA, connector, fuel cell, heat sink, lamination, LCD bonding, wafer bonding/polishing


nip impression, heat sealing


biomechanics, body mapping


brake pad, clamping, clutch, fuel cell, gasket bolted joint, impact study, lamination

Benefits of Tactilus®

  • Highly conformable and elastic sensor.
  • True calibration. Now NIST traceable.
  • No cumbersome external electronics. They're safely built into the sensor.
  • No training required. Hit the ground running.
  • Durability like no other sensor.

Sensor Specifications



Pressure Range

0.1 to 200 PSI (0.007 to 14.1 kg/cm2)

Matrix Size

Up to 64 x 256 lines


From 12 mils (0.3 mm)

Mat Sensor Size

Customizable up to 150" (381 cm)

1Scan Speed

Up to 1,000 hertz

Min Sensing Point Size

0.188 in2 (1.21 cm2)


Up to 158%


± 10%


± 2%


± 5%


NIST Traceable

2Software Compatibility

Windows 8, 7, XP

1) Only for some configurations with fewer sensing points.

2) An API can be provided to users who need to real-time connectivity to their own software.

Tactilus Packag: Bodyfitter - Mattress Surface Pressure Mapping

Tactilus bodyfitter is the next generation of surface pressure mapping for mattress stores. Taking over 25 years of pressure mapping experience and incorporating all the data collected into a single intuitive screen Bodyfitter provides the most powerful presentation on the market. Just by virtue of having the Bodyfitter system in house you'll see an increase in floor traffic.

Key Benefits:

  • Increase sales revenue by up-selling one level.
  • Lower post-purchase dissonance, translates into fewer product returns.
  • Faster time to sale.
  • Lends "scientific" validity to an otherwise subjective process.
  • Vastly improve your ability to track sales performance, effectiveness and efficiency.
  • Sharply reduces comfort exchanges.

Tactilus Packag: Bodyfitter - Mattress Surface Pressure Mapping

The real benefit is the conversion rate stimulated by Bodyfitter; by engaging the customer in this short but powerful scientific journey you're strengthening the bond and helping establish trust between customer and store. Simply by allowing a consumer to see their pressure profile increases store traffic. Bodyfitter allows the salesperson to convey to the consumer the benefits of pressure mapping with confidence and scientific credibility.

Tactilus works on what we call the "neutral mattress concept." Instead of moving your pressure mapping sensor around from bed to bed which is cumbersome and inconvenient, a neutral bed with an adjustable base is used. Our totally new software is extremely user friendly and is designed to be used wirelessly with a Windows based tablet. This provides the customer (and salesperson) an unprecedented level of convenience and speed. In literally seconds the customer can observe the substantial benefit to be gained by employing a power (adjustable) base.

Topaq® Pressure Analysis System

Topaq® is a revolutionary stress measurement instrument for analyzing force distribution and magnitude. Topaq®'s user-friendly Windows based software enables the characterization of how force is disbursed in any process or assembly where two surfaces contact or impact. Sensor Products Inc. is a world leader in the design and manufacture of sensor systems exclusively for tactile pressure monitoring and analysis.

A World of Uses

Sensor Products Inc. draws on over ten years of experience to continuously extend the capabilities of tactile pressure management. With the introduction of Topaq®, engineers now have a truly affordable tool of unparalleled power and accuracy. Whether your function is R&D, design or quality assurance, Topaq® improves yield, ensures parallelism, registers the precise characteristics of an impact, validates press uniformity and aids in all types of machine calibration.

A World of Uses

Sensor Products Inc. draws on over ten years of experience to continuously extend the capabilities of tactile pressure management. With the introduction of Topaq®, engineers now have a truly affordable tool of unparalleled power and accuracy. Whether your function is R&D, design or quality assurance, Topaq® improves yield, ensures parallelism, registers the precise characteristics of an impact, validates press uniformity and aids in all types of machine calibration.

Unlike FEA, Topaq® is a post-process interpretive system that actually collects data from a proprietary tactile transducer.

Powerfully Simple to Use

While Topaq® is equipped with an extensive array of features, you can perform a simple analysis in a matter of minutes. The system makes it extremely easy for a new user to extract and utilize important information. Simply scan in your exposed pressure indicating film, key in a few input variables, and Topaq® instantly generates full-color pressure maps and accompanying statistical data. Even more, Topaq® is accurate to within ± 4% - unprecedented in the field of tactile pressure measurement.

A Better Way of Looking at Pressure

Pressure Line Scans: One example of Topaq's powerful, single keystroke features is the ability to determine the pressure profile along a user-defined line. This line can be reduced to the width of a pixel, or expanded as wide as the image itself. This is a useful tool for assessing narrow bands of pressure over unusual or intricate shapes.

Pressure Statistics: The region statistics function yields total force, average PSI (or metric Kg/cm) and standard deviation for the entire image or a user-defined region.

A Better Way of Looking at Pressure

Pressure Distribution Histograms: Topaq® reads and interprets pressure variation by optically analyzing your pressure indicating sensor films and assimilating this data into a series of easy-to-read formats. A single keystroke generates the Histogram, a report that reveals the statistical distribution of pressure levels throughout your image. Of course, as with all Topaq® functions, you can perform a Histogram on a user-defined region of interest.

Topaq's Grid-maker function can divide your image into any number of user-defined quadrants. The software then automatically calculates statistical information for each segment.

Auto-Nis® - The Complete Nip Impression Solution

Tired of the Painstaking Manual Nip Impression Measurements?

Sensor Product's Automated Nip Impression System (Auto-Nis®) brings science to the nip impression measurement process. Auto-Nis® is an optical analysis system that is used in conjunction with Fujifilm Prescale® film as well as standard carbon papers.


Regular nip impressions ensure proper roller alignment and crowning, significantly reducing machine downtime and improving yield.

  • Optical analysis instrument reads and interprets nip width and nip pressure data.
  • Data is immediately captured and assimiliated into easy to read graphs on your laptop.
  • The scanning unit (DocketScan) connects directly into the USB port on your laptop.

Benefits For You

  • Scans and interprets BOTH nip width and nip pressures
  • Scans and interprets BOTH Fujifilm Prescale® and conventional carbon paper.
  • Scientific exactitude in nip measurements.
  • Fast, efficient and accurate results.
  • Very small and portable only 16 ounces - fits in your brief case.
  • Powerful reports.