The newly developed thin-film temperature sensor technology was specifically designed for use in high-current transmission applications. The technology makes it possible to measure temperature trends directly at the point of action, thereby enabling real-time monitoring of particularly critical conditions in electrical contacts. Especially in the charging infrastructure for electric mobility, where high currents must be transmitted safely, this form of direct measurement contributes significantly to operational safety and extends the service life of components.

The sensor technology can either be applied directly to copper contact elements or integrated in the form of flexible, cost-effective polyimide film inserts. This results in an application-specific, customizable solution that enables both high-precision measurements directly at the point of contact and easy integration into existing systems. At the same time, the modular approach allows for the straightforward replacement of contact components as needed. Both variants are designed for use in high-current contacts and can be viewed at the exhibition stand.

The particular benefit of these developments lies in the early detection of critical temperature conditions that can arise, for example, due to faulty contact conditions. This helps to prevent potential damage to charging infrastructure components before safety-related thresholds are reached. At the same time, the technology enables predictive maintenance, as the condition of the contacts is continuously monitored, thereby optimizing maintenance intervals. In addition to electromobility, this creates opportunities in power electronics, busbars, and stationary and mobile energy storage systems, among others.

With the developments presented, Fraunhofer IST demonstrates how thin-film sensor technology opens up new possibilities for condition monitoring in applications with high electrical loads, thereby making an important contribution to the safe and efficient use of energy in the future. The institute’s experts look forward to exchanges with trade visitors at Sensor+Test 2026 in Nuremberg.