5 Ways Sensors Increase Safety and Reduce Maintenance Costs in Infrastructure Projects

Infrastructure like bridges, tunnels, and buildings is designed to last for decades — but time, weather, and wear take their toll. Engineers today rely on sensors for infrastructure monitoring to ensure that these critical structures stay safe, reliable, and cost-effective to maintain.

Here are five ways advanced sensor technology — like ElastiSense Sensor Technology’s solid-state displacement sensors — is transforming the way we manage infrastructure.

1. Real-Time Condition Monitoring

With modern sensor technology, engineers can monitor bridges, tunnels, and dams in real time. This continuous flow of data allows them to detect shifts, cracks, or displacement before they become safety concerns — replacing reactive maintenance with proactive insight.

2. Early Warning Systems for Structural Issues

Traditional inspections can miss gradual changes that indicate trouble ahead. Sensors make it possible to identify early warning signs — like small cracks or unexpected movements — and act before a minor issue becomes a costly or dangerous failure.

3. Lower Maintenance Costs

Manual inspections are time-consuming, expensive, and sometimes risky. By deploying sensors for infrastructure monitoring, maintenance teams can reduce site visits, focus resources where they’re truly needed, and avoid unnecessary downtime.

4. Enhanced Safety for People and Assets

When sensors are in place, engineers and operators can work with confidence. Automated alerts and data visualization tools make it easy to assess risks remotely, protecting both the structure and the people who depend on it.

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5. Extending the Lifespan of Infrastructure

By identifying stress, displacement, and other structural challenges early, sensor data helps extend the lifespan of infrastructure — supporting predictive maintenance strategies that save millions over time while improving sustainability.

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Smarter Monitoring with ElastiSense Sensor Technology

At ElastiSense, we’re proud to contribute to safer, smarter infrastructure with our solid-state displacement sensors. Built for harsh environments and long-term reliability, they deliver the data engineers need to make informed decisions and keep the world’s infrastructure standing strong.

👉 Learn more about our sensors for infrastructure monitoring here: https://elastisense.com/products-sensor-solution/structural-health-monitoring/

Have you ever heard of revolutionary sensors made from silicone rubber? Neither had we, until we walked through the doors of ElastiSense Sensor Technology (EST). We can’t wait to share our unforgettable experience during our internship!

We are Marianne and Celine, 16-year-old twins. When our school offered us a two-week internship, we knew immediately that ElastiSense Sensor Technology was the place for us.

Our adventure began on October 6th. For two weeks, from 8:30 a.m. to 3:00 p.m., the team at EST welcomed us with open arms. On our first day, Sales and Marketing Director Kenneth Bloch Sørensen gave us a comprehensive tour and shared the company’s fascinating history. We learned that EST was founded in 2023, emerging from two businesses: LEAP technology (2013) and ElastiSense (2016) driven by the remarkable ambition of CEO Benjamin Thomsen and CMO Kenneth Bloch Sørensen. EST sells its groundbreaking sensors and accessories globally. Their goal is to forever change the sensor market.

Mr. Thomsen then introduced us to the various products and the science behind them. Did you know these sensors have hundreds of different applications, from Structural Health Monitoring to Factory Automation Monitoring? It was truly fascinating! Even more impressive, sensors like the Displacement Sensor (DS-Sensor) offer thousands of different variations.

The most exciting part was the practical work. With help from the Production Manager, we produced our own high-quality sensors.

We are so grateful to the EST team for being patient, making time for us, and always being open to our many questions. Over the two weeks, our horizons expanded beyond production to include marketing and programming.

Ultimately, our internship at ElastiSense Sensor Technology provided us with a profound look into the company. We are incredibly thankful for the opportunity to have produced our own sensors and to have gained a deeper understanding of the captivating world of sensor technology. This experience taught us what it truly takes to create and commercialize such an outstanding product.

We also made a short video of our internship:

Customizable Stretch Sensors – Tailoring Technology to Your Application

In the world of smart wearables, robotics, and performance technology, one sensor doesn’t fit all. Every project has unique requirements — from stretch range and material flexibility to signal output and integration method. That’s why ElastiSense Sensor Technology offers customizable stretch sensors, giving designers, engineers, and researchers the freedom to shape technology around their ideas, not the other way around.

Why Customization Matters

When developing innovative products — whether a rehabilitation device, a biomechanical performance tracker, or a soft robotic system — precision and flexibility are everything. Off-the-shelf sensors often can’t deliver the exact range, elasticity, or responsiveness needed for optimal performance.

With customizable stretch sensors, ElastiSense Sensor Technology enables customers to specify how the sensor behaves, feels, and communicates — ensuring a perfect fit for even the most advanced applications.

What Can Be Customized?

Our stretch sensor technology is built for flexibility — literally and technically.
You can tailor parameters such as:

• Stretch range – From small extensions to large elastic movements.

• Signal output – Match your preferred interface or microcontroller.

• Cable type and length – Configure to fit your product or prototype setup.

• Sensor form and material – Adjust size, flexibility, and design for comfort and durability.

• Color and finish – Align with your product design or visibility needs.

Perfect for Medical, Sports, and Robotics Applications

Our customizable stretch sensors have proven ideal for:

• Medical wearables & rehabilitation devices – Measure movement, posture, respiration and strain with precision.

• Sports performance technology – Capture motion, respiration, muscle activity, and flexibility data in real time.

• Soft robotics – Enable lifelike movement, tactile feedback, and adaptive control.

• Research and prototyping – Give universities and innovators a fast, adaptable way to test new ideas.

From Concept to Creation

At ElastiSense Sensor Technology, we believe innovation thrives when the technology adapts to the user — not the other way around. Our engineers work closely with you to define your needs, fine-tune your design, and deliver a sensor that performs exactly as required. Whether you’re creating a new product or refining an existing prototype, our customizable stretch sensors make it possible.

Innovation Without Limits

When precision meets flexibility, possibilities multiply. With our customizable stretch sensor technology, you can take your product or research to the next level — accurately, reliably, and your way.

👉 Learn more about our customizable stretch sensors here: https://elastisense.com/stretch-sensors/

ElastiSense Lowers Prices on Wireless Measurement Box and Stretch Sensor Kit by Over 30%!

At ElastiSense, we are excited to announce a significant price reduction on two of our most popular products:

• Wireless Measurement Box – now just 605 €

• Stretch Sensor Kit – now only 803 €

That’s a price drop of more than 30%, making it easier than ever to explore and apply our cutting-edge sensor technology in your projects.

We’ve made this change to better support students, universities, and companies working on development projects. Both the Wireless Measurement Box and Stretch Sensor Kit are ideal tools for studies and experiments within:

• Wearable technology for medical and sports applications

• Robotics and automation systems

• Machinery monitoring and other industrial technologies

• Innovation and product development across all sectors

Whether you’re conducting academic research, developing prototypes, or innovating in industry, ElastiSense provides flexible, reliable, and easy-to-integrate sensing solutions to help you succeed.

👉 Order directly from our webshop here: Visit the ElastiSense Webshop

Don’t miss this opportunity to get professional-grade sensing technology at a new, more accessible price.

What Makes Solid-State Displacement Sensors More Reliable?

In demanding industries like infrastructure monitoring, heavy vehicles, and factory automation, reliability is everything. When equipment or monitoring systems fail, the consequences can be costly — or even dangerous. That’s why many industries are moving away from traditional sensor technologies, like LVDTs, and adopting solid-state displacement sensors. But what makes them more reliable?

The Limitations of Traditional Sensors

Conventional displacement sensors often include moving parts, coils, or delicate mechanical elements. These components are prone to wear, misalignment, and damage in harsh conditions, resulting in frequent recalibration and higher maintenance costs.

Why Solid-State Sensors Excel in Reliability

Solid-state displacement sensors, such as the DS Series from ElastiSense Sensor Technology, are built without moving parts. This design brings several advantages:

• No wear and tear – With no moving elements, sensors maintain accuracy over long lifespans.

• Resistance to harsh environments – Dust, vibration, water, and temperature extremes don’t compromise performance.

• Stable long-term accuracy – Less drift and fewer recalibrations mean consistent results.

• Low maintenance – Reduced downtime and fewer replacements save time and money.

Applications That Depend on Reliability

• Structural Health Monitoring – Continuous, long-term monitoring of bridges and tunnels.

• Heavy Vehicles – Load and suspension monitoring in mining and construction equipment.

• Factory Automation – Real-time monitoring of positioning and machine movement.

• Energy & Utilities – Reliable performance in turbines, power plants, and critical infrastructure.

Long-Term Value of Solid-State Sensors

Reliable sensors aren’t just about preventing failure — they’re about enabling predictive maintenance, improving safety, and cutting operational costs. Solid-state displacement sensors deliver confidence in the data, which in turn ensures smarter decisions and safer operations.

ElastiSense – Built on Reliability

At ElastiSense, reliability is at the heart of our design. Our DS Series sensors deliver precision, durability, and long-term stability that industries worldwide can trust.

👉 Learn more about our reliable solid-state displacement sensors: https://elastisense.com/products-sensor-solution/

👉 Contact us directly for more information, orders or quotes.

10 Industries That Benefit from Modern Displacement Sensors

Sensors are essential tools in today’s technology-driven world. By providing precise, real-time measurements of movement and position, they enable smarter decisions, greater efficiency, and higher safety standards. At ElastiSense Sensor Technology, our DS Series solid-state sensors and stretch sensor technology are redefining what’s possible across multiple sectors. Here are 10 industries that benefit most from our sensor technology.

1. Structural Health Monitoring

From bridges to tunnels, sensors track displacement and cracks, ensuring infrastructure safety and longevity.

2. Civil Engineering

Engineers rely on sensors for construction monitoring, settlement detection, and validating project safety.

3. Heavy Vehicles

Mining trucks, construction machines, and transport fleets use sensors to monitor stress, load, and suspension.

4. Factory Automation

Automation systems depend on reliable sensors for positioning, quality control, and predictive maintenance.

5. Robotics

Precise motion tracking enables robotics to operate with accuracy in manufacturing and research.

6. Aerospace

Aircraft testing and maintenance benefit from highly reliable displacement monitoring solutions.

7. Automotive

From R&D crash testing to production quality control, displacement sensors ensure performance and safety.

8. Energy Sector

Power plants and turbines require long-term monitoring of displacement under extreme conditions.

9. Academia & Research

Researchers use sensors in biomechanics, materials testing, and prototyping for innovation and discovery.

10. Medical Technology

Wearables and rehabilitation devices gain valuable insights from stretch and displacement measurements.

The Future of Displacement Sensing

As industries continue to evolve, the need for robust, accurate, and low-maintenance sensor technology grows. Solid-state DS Sensors and stretch sensors from ElastiSense Sensor Technology meet this demand, delivering the precision and durability that traditional technologies cannot match.

👉 Learn more about ElastiSense displacement sensors: https://elastisense.com/products-sensor-solution/ or our stretch sensor technology: Stretch Sensors

Solid-State Sensors: Reducing Downtime in Industrial Environments

In today’s competitive industrial landscape, downtime is costly. Every minute of halted production can mean lost revenue, delayed deliveries, and unhappy customers. One of the smartest ways to prevent downtime is to use solid-state displacement sensors, which provide reliable, real-time monitoring without the fragility and high maintenance demands of older sensor technologies.

The Problem with Traditional Sensors

Conventional displacement sensors, such as LVDTs, have moving parts and delicate components that can quickly wear out in harsh industrial conditions. Dust, vibration, temperature shifts, and moisture make these sensors prone to failure. This leads to more frequent maintenance, higher costs, and unexpected breakdowns.

Why Solid-State DS Sensors Are the Better Choice

ElastiSense DS Sensors are fully solid-state, meaning they contain no moving parts. This gives them unique advantages in industrial environments:

• Rugged durability – Resistant to dust, vibration, shocks, and moisture.

• Low maintenance – Fewer breakdowns and no need for frequent recalibration.

• Real-time monitoring – Accurate data for predictive maintenance strategies.

• Easy integration – Plug-and-play design fits seamlessly into automation systems.

Industrial Applications Where Solid-State Sensors Excel

• Factory automation – Continuous monitoring of machine movements to reduce production errors.

• Heavy equipment – Monitoring stress and displacement under high loads.

• Energy sector – Ensuring stability in turbines, generators, and critical equipment.

• Infrastructure – Long-term monitoring in tunnels, bridges, and other harsh environments.

Reducing Downtime with Predictive Maintenance

By providing reliable, continuous data, DS Sensors enable predictive maintenance—detecting small issues before they cause major failures. This reduces downtime, extends equipment lifespan, and lowers total cost of ownership.

ElastiSense Sensor Technology – Building the Future of Industrial Monitoring

At ElastiSense, our mission is to deliver robust, accurate, and maintenance-free displacement sensors that thrive in the toughest industrial settings. With DS Sensors, companies can protect their operations and maximize productivity.

👉 Learn more about solid-state displacement sensors: https://elastisense.com/products-sensor-solution/

How Displacement Sensors Drive Smarter Factory Automation

Modern factories depend on automation to deliver high efficiency, productivity, and reliability. But to make automation truly “smart,” accurate and durable sensor technology is essential. Displacement sensors for factory automation provide the real-time data needed to ensure machines and processes run smoothly—with fewer interruptions and lower costs.

The Need for Real-Time Monitoring in Factories

Automation systems rely on constant feedback to operate efficiently. Small errors in machine positioning, alignment, or movement can result in costly downtime, wasted materials, and reduced product quality. Traditional displacement measurement technologies like LVDTs often struggle in harsh industrial environments where dust, vibration, and temperature fluctuations are the norm.

Why Solid-State DS Sensors Outperform Traditional Options

The DS Series Sensors from ElastiSense are designed for today’s factory challenges. Unlike traditional sensors with moving parts, DS Sensors are fully solid-state, making them robust, reliable, and maintenance-free.

Key advantages for factory automation:

• Real-time data – Continuous monitoring of machine movement and positioning.

• Durability – Resistant to vibration, dust, and environmental stress.

• Easy integration – Plug-and-play installation in existing automation systems.

• Cost reduction – Lower maintenance and fewer breakdowns mean higher productivity.

Applications Across Factory Automation

• Assembly lines – Ensure precise positioning of parts for high-speed manufacturing.

• Robotics – Enable accurate, repeatable motion in robotic arms and automation systems.

• Quality control – Track displacement during inspection and testing to guarantee consistency.

• Predictive maintenance – Detect wear and misalignment early to prevent costly failures.

The Future of Automation with DS Sensors

As factories become increasingly digital and connected, reliable sensor technology is the foundation for Industry 4.0. DS Sensors provide the intelligence needed to drive smarter automation, helping manufacturers boost efficiency, improve quality, and remain competitive.

ElastiSense Sensor Technology – Supporting Smarter Factories Worldwide

At ElastiSense, we deliver displacement sensors that combine precision, durability, and simplicity. Whether you’re automating production lines, robotics, or predictive maintenance, DS Sensors are designed to keep your factory running smarter and smoother.

👉 Learn more about our displacement sensors for factory automation: DS Sensors or contact us directly for more information, quotes, or sensors for testing.

Heavy vehicles—from mining trucks and excavators to construction machinery and transport fleets—face extreme conditions every day. To ensure safety, efficiency, and long service life, displacement sensors for heavy vehicles are becoming an essential technology.

The Challenges of Monitoring Heavy Vehicles

Heavy-duty vehicles operate under intense mechanical stress, carrying heavy loads, navigating uneven terrain, and enduring constant vibration. Traditional monitoring solutions are often too fragile, complex, or high-maintenance to withstand these environments. This makes it difficult for operators to predict failures or optimize performance.

Why Solid-State DS Sensors Are Ideal for Heavy Vehicles

ElastiSense DS Sensors provide a robust, solid-state solution that is specifically designed to perform in harsh environments. With no moving parts, they are more durable, reliable, and easier to integrate than traditional technologies like LVDTs.

Key benefits include:

• Load monitoring – Track stress on suspension systems and frames to avoid overload.

• Suspension displacement measurement – Improve stability and performance while reducing wear.

• Vibration resistance – Accurate data even under constant shaking and shocks.

• Low maintenance – Solid-state design means reduced downtime and repair costs.

Applications in Mining, Construction, and Transport

• Mining trucks – Monitor frame displacement and suspension under massive payloads.

• Construction machinery – Ensure excavators, bulldozers, and cranes remain stable and safe.

• Transport fleets – Improve reliability and reduce breakdowns in logistics and heavy haulage.

How Displacement Sensors Extend Vehicle Lifespan

By providing real-time, actionable data, DS Sensors allow operators to adopt predictive maintenance strategies. Instead of reacting to breakdowns, fleet managers can schedule repairs before small issues become major problems—saving both time and money while improving safety.

ElastiSense – Driving Innovation in Heavy Vehicle Monitoring

With proven durability and plug-and-play functionality, ElastiSense displacement sensors are helping industries worldwide keep their vehicles running longer, safer, and smarter.

👉 Learn more about DS Sensors here: https://elastisense.com/products-sensor-solution/ or contact us for more information.

Why Bridges and Tunnels Require Continuous Monitoring

Bridges and tunnels are critical to modern transportation networks. They support enormous daily traffic loads, withstand environmental stress, and must remain safe and reliable for decades. Even small structural changes, such as displacements or crack formation, can compromise safety and lead to costly repairs. This is why continuous monitoring with displacement sensors has become essential in civil engineering and infrastructure management.

Traditional Monitoring Methods vs. Solid-State Sensors

In the past, inspections were largely manual, requiring engineers to visually check structures or use instruments that offered only periodic data. These methods are labor-intensive, slow, and often miss early warning signs.

Solid-state displacement sensors, such as the DS Series from ElastiSense, represent a new generation of monitoring technology. Unlike traditional LVDTs or mechanical systems, DS Sensors are robust, easy to install, and deliver continuous real-time data—making them ideal for long-term monitoring projects.

Benefits of Using DS Sensors in Infrastructure Projects

• Real-time data – Immediate insight into structural performance and changes over time.

• Durability in extreme conditions – Resistant to dust, water, vibration, and temperature fluctuations.

• Predictive maintenance & cost savings – Detect issues early, reducing repair costs and preventing catastrophic failures.

• Simple integration – Compact and solid-state, requiring no special protection or alignment.

Case Examples: Bridge & Tunnel Monitoring with DS Sensors

• Bridges – Monitoring displacement and expansion joints, ensuring that load-bearing structures remain within safe parameters.

• Tunnels – Detecting settlement or ground movement, helping engineers anticipate risks from soil pressure or water ingress.

These applications highlight how DS Sensors provide continuous, reliable, and precise monitoring where human inspection alone would fall short.

The Future of Structural Health Monitoring with ElastiSense Sensor Technology

As infrastructure ages and demands on it grow, solid-state displacement sensors are becoming the backbone of modern monitoring systems. At ElastiSense, we are proud to deliver sensors that help engineers, cities, and communities protect their most critical assets—bridges and tunnels included.

👉 Learn more about our displacement sensors here: https://elastisense.com/products-sensor-solution/

You are also welcome to contact us directly, if you need more information or advice.