A Novel Shape Reconstruction Technique Using Flexible Differential Inductive Sensor Array

Lei Peng

doi:10.1109/tim.2026.3742085

A Novel Shape Reconstruction Technique Using Flexible Differential Inductive Sensor Array

2026-10-19

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DOI：10.1109/tim.2026.3742085

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Accurate shape sensing is crucial in robotics, biomedical engineering, and structural health monitoring for tasks like robotic guidance and infrastructure assessment. However, challenges such as dealing with complex geometries during sensing and data acquisition while maintaining high accuracy remain. This study introduces a flexible differential inductive sensor array for 2D shape sensing and reconstruction. The system employs two FPCB-based inductive sensor strips, separated by a fixed distance, to measure curvature through relative inductance shifts. The differential design suppresses background noise and improves signal to noise ratio. A 3D finite element model (FEM) was developed for feasibility and parametric studies that lead to sensor array optimization. Simulation results showed that smaller spacing distance of transmitter and receiver coils extends the dynamic range of measurable curvature, while larger spacing enhances resolutions for larger curvature measurement. For experimental validation and demonstration, a prototype system was fabricated, incorporating a 3D-printed flexible mount, a miniaturized circuit system, and shape reconstruction algorithms. The results show that the system can measure the arc shape with an average maximum positional error of 1.97% for curvature radii ranging from 40 mm to 100 mm, and 2.45% for radii ranging from 40 mm to 400 mm. The system was also tested on two irregular shapes, achieving an average error of 1.25%. Its capability was further demonstrated through 3D geometry reconstruction of a dented pipe structure. These results highlight the system's high accuracy, superior resolution, and great adaptability for various potential applications, offering valuable insights and advances for optimizing shape sensing.

Keywords:

Inductive sensing

flexible sensor array

shape reconstruction and sensing

curvature measurement

nondestructive evaluation

structure health monitoring

A Novel Shape Reconstruction Technique Using Flexible Differential Inductive Sensor Array

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