Attach the sensors to the measurement point
The mount is designed to fit the specific sensor and installation conditions. This allows the sensor to be mounted exactly where the measurement data is needed during vehicle testing.
3D-Printed Sensor Mounts for Vehicle Testing
A custom sensor mount for test vehicles, tailored to the available installation space, the sensor, and the specific measurement task. Additively manufactured for a development project in which requirements change rapidly.
When the measurement point is critical
During a vehicle test, a development team needs to measure vibrations in a suspension component. To do this, the sensor must be mounted at a specific location and held securely in place during the measurement. However, there is no suitable mounting point on the component itself. A standard mount either does not fit within the tight installation space or cannot be aligned at the desired angle.
Designing a complex custom solution for a one-time test setup takes time. And if the installation situation changes in the next development phase, the adaptation process starts all over again.
This is exactly where a custom-made sensor mount can help.
The Solution: Tailored to the Vehicle, Sensor, and Measurement Task
The mount is designed to fit the intended mounting surface and the sensor being used. Mounting points, the sensor housing, and the installation space can be considered together. If necessary, cable routing or strain relief can also be integrated into the design.
If the vehicle geometry or the position of the measurement point changes, the bracket can be adapted and manufactured as a new variant. This provides the development team with a solution that fits the current test setup without having to produce a tool for a single component or one required in only small quantities.
Manufacturing Overview
Three different bracket geometries were required for the test run, and each variant was manufactured ten times. This allowed 30 brackets to be installed at 30 sensor positions in two test vehicles.
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What the sensor holder enables during test operation
Set the Position and Orientation
The sensor mount and mounting points can be designed to suit the specific measurement task. This allows the sensor to be precisely aligned and repeatedly mounted in the test setup.
Create Variants for New Vehicle Stands
If the mounting surface or installation space changes, the bracket geometry can be adjusted. Individual parts and variants can be manufactured using additive manufacturing without the need to produce a separate tool.
Frequently Asked Questions About the Sensor Holder
Does a 3D-printed mount distort vibration measurements?
Not if it’s designed to be stiff enough. Every mount has its own natural frequency, and that should be well above the frequency range you’re measuring. Short lever arms, ribs, and a stiff material such as glass-fiber-reinforced PA12 increase the natural frequency. For critical measurements, it’s worth performing an impact test on the finished mount.
Can you print threads directly into the holder?
For screws that are loosened frequently, this is not recommended: Printed plastic threads wear out quickly. Metal threaded inserts or through-holes with nuts are more reliable. Please specify in your inquiry how often the sensor will be repositioned, and we will take this into account when reviewing your data.
What do you need to make a sensor holder?
Ideally, a CAD model of the mount as a STEP file. For the analysis, additional information about the sensor, installation orientation, and environmental conditions—such as temperature, water spray, or oil—is also helpful. This allows for the selection of an appropriate material.
Are you developing a component for a vehicle or a test rig?
In addition to sensor mounts, we manufacture custom plastic and metal components for prototypes, test vehicles, and test rigs. Send us your CAD data or describe your requirements, and we’ll determine which manufacturing process and material are suitable.
Learn more: 3D Printing for the Automotive Industry
Ready for your first prototype? Talk to us.
Onur Yildirim
Head of Sales, Additive Manufacturing
Fislisbach, Switzerland