Thin Film Technology in Sensor Manufacturing – A Technical Discussion

Year : 2026 | Volume : 13 | Issue : 01 | Page : 48 58
    By

    Heena T. Shaikh,

  • Kazi Kutubuddin Sayyad Liyakat,

  1. Assistant Professor, Department of Electronics and Telecommunication Engineering, Brahmdevdada Mane Institute of Technology, Solapur, Maharashtra, India
  2. Professor and Head, Department of Electronics and Telecommunication Engineering, Brahmdevdada Mane Institute of Technology, Solapur, Maharashtra, India

Abstract

Thin‑film technology has become the cornerstone of modern sensor manufacturing, enabling the convergence of miniaturisation, multifunctionality, and cost‑effective mass production. This paper surveys the latest advances in deposition techniques—ranging from magnetron sputtering and chemical vapour deposition to atomic‑layer deposition (ALD) and ink‑jet‑printed sol‑gel processes—and examines how their unique material‑control capabilities translate into performance gains across the sensor spectrum (chemical, physical, and bio‑sensing). By integrating nanoscale thickness control (≤ 10 nm) with engineered micro‑architectures (e.g., porous nanolayers, multilayer stacks, and gradient‑index films), developers can tailor electrical, optical, and mechanical transduction pathways with unprecedented precision. Case studies on gas‑phase metal‑oxide chemiresistors, piezo‑electric MEMS pressure sensors, and plasmonic biosensors illustrate the synergistic relationship between film composition, micro‑structure, and signal fidelity. Benchmarking against conventional bulk‑sensor platforms reveals that thin‑film‑based devices achieve up to a 60 % reduction in power consumption, a 3‑fold increase in detection limit, and a 40 % improvement in response time, while maintaining compatibility with flexible and wearable substrates. The discussion highlights critical challenges—such as interfacial stress, long‑term stability, and scalable patterning—paired with emerging solutions like in‑situ plasma‑assisted annealing and machine‑learning‑guided process optimization. The analysis concludes that thin‑film technology not only accelerates the trajectory toward ubiquitous, high‑performance sensors but also opens new avenues for hybrid‑sensor ecosystems that integrate energy harvesting, on‑chip data processing, and wireless communication. Furthermore, the integration of advanced characterization tools—such as in situ spectroscopic ellipsometry and high resolution electron microscopy—enables real time monitoring of film growth dynamics, ensuring reproducibility and process scalability. These developments strengthen the transition from laboratory scale innovation to industrial sensor fabrication.

Keywords: Gas sensor, pressure sensor, sensor, thin film, vapor deposition

[This article belongs to Journal of Thin Films, Coating Science Technology & Application ]

How to cite this article:
Heena T. Shaikh, Kazi Kutubuddin Sayyad Liyakat. Thin Film Technology in Sensor Manufacturing – A Technical Discussion. Journal of Thin Films, Coating Science Technology & Application. 2026; 13(01):48-58.
How to cite this URL:
Heena T. Shaikh, Kazi Kutubuddin Sayyad Liyakat. Thin Film Technology in Sensor Manufacturing – A Technical Discussion. Journal of Thin Films, Coating Science Technology & Application. 2026; 13(01):48-58. Available from: https://journals.stmjournals.com/jotcsta/article=2026/view=241653


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Regular Issue Subscription Review Article
Volume 13
Issue 01
Received 24/02/2026
Accepted 25/02/2026
Published 25/03/2026
Publication Time 29 Days
12

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