Tactile Sensor Integration: A Case Study in Precision Engineering
- Marta Garcia Caberol
- Jan 16
- 3 min read
At Touchlab, we believe that for robots to truly coexist and collaborate with humans, they need more than just sight and sound—they need the power of touch. Our recent collaboration with Prensilia provided a unique opportunity to demonstrate how our advanced technology for tactile sensor integration can be seamlessly integrated into world-class robotic platforms.
The project began in early April 2025 with a set of high-priority requirements from Prensilia:
REQ-001: Deliver a sensorised thumb integrated with 16 taxels and supporting electronics.
REQ-002/003: Ensure full compatibility with the MIA hand, maintaining mechanical movement while routing cables without interfering with internal structures.
REQ-005/006: Preserve the original thumb's appearance and use the same materials as the MIA hand to ensure compatibility and manufacturability.
The Challenge: Adding Senses to the MIA Hand
The project, which ran from May to July 2025, focused on a high-priority goal: integrating Touchlab's fingertip technology into the thumb of Prensilia's sophisticated MIA Hand.
This wasn't a simple "plug-and-play" task. Our team faced several significant hurdles:
Space Constraints: The thumb's internal structure created design conflicts with our fingertip sensors.
Complex Routing: Navigating PCB and cable routing within a limited space required extreme precision to avoid interfering with mechanical movements.
Maintaining Integrity: The final solution had to maintain the thumb’s original strength, sensor performance, and overall appearance.
Our Approach: A 12-Week Journey to Tactile Sensor Integration
To meet Prensilia's rigorous requirements, the Touchlab team followed a structured timeline that prioritised both speed and technical rigour:
Phase 1: Conceptual Design (2 Weeks): We assessed mechanical, electrical, and interface constraints to define detailed technical tolerances.
Phase 2: Custom Engineering (4 Weeks): Our team designed a custom internal thumb structure to resolve space conflicts while maintaining the component's original strength and movement. To maximise space and fulfil the design requirements for the MIA hand, we specifically relocated the PCB to the base of the finger and integrated a custom-designed flat cable routed carefully through the internal structure. This custom adapter allowed us to reuse our core sensor film and electronics while ensuring the new assembly stayed strictly within the maximum dimensions specified by the client.
Phase 3: Calibration & Fixture Design (4 Weeks): Working in parallel, we updated our calibration stages and designed specific fixtures for the MIA hand.
Phase 4: Integration & Validation (4 Weeks): The final weeks focused on post-processing, assembly, and rigorous sensor testing and/or calibration to ensure signal integrity.
Validated Reliability: The Destructive Test
A good design not only fulfils the sensing requirements but also needs to be robust enough to sustain high load. On May 17, 2025, Lead Test Engineer Zach Keane conducted a formal destructive test at Touchlab HQ to validate the structural integrity of the designed thumb.
Mecmesin OmniTest 2.5 was used with a custom built fixture. A high load of 60-Newton was applied to the thumb for 30 seconds. The results of this tactile sensor integration test were conclusive:
Structural Integrity: Post-test analysis revealed no fatigue, cracks, or structural issues.
Sensor Performance: The 16-taxel sensor provided consistent and reliable data throughout the entire loading and unloading phase.
The Result: A Path to Production
In just a few months, Touchlab took a complex design challenge and delivered a fully-realised, manufacturable product. By developing a custom finger and protective cover that stayed strictly within Prensilia's specified dimensions, we ensured both functionality and aesthetic continuity.
The design is now fully aligned with Prensilia’s manufacturing process and is scalable for future production. By combining Prensilia's elegant robotics with Touchlab's "human touch," we aren't just building better machines—we're building the future of interaction.
Ready to Sensorise Your Hardware?
Whether you are working on prosthetic limbs, industrial grippers, or collaborative robots, Touchlab can help you bridge the gap between mechanical action and tactile intelligence.
