Aerospace test environments demand pressure data that holds up under extreme temperatures, rapid pressure changes, and prolonged vibration cycles. A single measurement error during an engine test or flight validation campaign can invalidate weeks of data and delay a program's schedule.
This article explains how aerospace pressure sensors are selected and used in precision test stands and flight test programs. You will learn what drives sensor drift, how calibration practices protect measurement integrity, and which selection criteria matter most for long-term stability.
STS Sensors delivers high-precision pressure measurement technology tailored to the demanding conditions of aerospace testing, from turbopump validation to cabin pressure monitoring.
Aerospace pressure sensors are instruments that convert gas or fluid pressure into an electrical signal. In aerospace, these sensors monitor fuel lines, hydraulic systems, cabin environments, and engine performance parameters during both ground testing and flight.
Unlike general industrial sensors, aerospace variants must perform reliably under conditions that include wide temperature swings, high-frequency vibration, and exposure to aggressive media. Piezoresistive sensing elements are widely used in these applications because they offer fast response times and high resolution across broad pressure ranges.
The electrical output from these sensors, typically 4-20 mA or mV signals, feeds directly into test data acquisition systems. Accurate, repeatable data at this stage is what separates a valid test campaign from one that requires rerunning.
Test stands simulate operating conditions that an engine, turbopump, or hydraulic system will encounter in service. Pressure data collected during these tests informs design decisions, validates safety margins, and confirms compliance with qualification standards.
During flight testing, pressure sensors monitor parameters such as cabin pressure, fuel supply stability, and environmental control system (ECS) performance. Even small inaccuracies here can mask a developing fault or trigger false alarms in redundant monitoring logic.
A 2025 IEEE study on silicon piezoresistive pressure sensors found that long-term stability is the most critical performance metric for sensors deployed in high-stakes measurement environments, reinforcing the case for selecting sensors specifically engineered for drift resistance. You can find the study published in the 2025 IEEE ICMLCA proceedings.
Drift refers to a gradual shift in a sensor's output signal even when the actual pressure remains constant. In aerospace environments, three primary mechanisms drive this behavior.
Mechanical fatigue: Repeated pressure cycles, vibration, and shock loads cause micro-deformations in the sensing membrane. Over thousands of test cycles, these changes shift the sensor's zero point and alter its hysteresis characteristics.
Thermal cycling: Aerospace test environments often expose sensors to temperature ranges spanning -40 °C to well above 125 °C. Expansion and contraction of internal components changes the electrical characteristics of the sensing element, introducing measurement offset.
Electronic aging: Internal reference voltages and signal conditioning circuits degrade over time. In non-hermetically sealed housings, moisture ingress accelerates this process. The result is a slow, often undetected deviation from the sensor's original calibration.
Calibration is the process of comparing a sensor's output against a known reference standard and correcting any deviation. In aerospace test programs, calibration intervals are defined based on the sensor's documented long-term stability specification and the criticality of the measurement.
Factory calibration typically includes temperature compensation across the sensor's rated operating range. This step reduces thermally induced drift by mapping the sensor's behavior at multiple temperature points and applying correction coefficients to the output signal.
Regular recalibration during a test campaign catches drift before it corrupts data. However, sensors with lower inherent drift require fewer recalibration cycles, reducing downtime and the risk of handling-induced damage during removal and reinstallation.
Sensor selection for aerospace testing depends on a set of application-specific criteria. The following parameters are typically evaluated during the specification process:
STS Sensors manufactures piezoresistive pressure sensors and transmitters configured for aerospace test environments. The range covers absolute, gauge, and differential pressure measurement with accuracy options down to 0.05% FS.
The PZ770 miniature pressure sensor covers ranges from 1 to 413 bar with accuracy of 0.1% FS or better, operating from -40 °C to 150 °C. Its compact stainless steel housing was developed for applications with strict weight and space constraints.
STS Sensors has delivered over 3,500 sensors for aerospace applications in the last five years. The company recently supported Latitude Space with pressure sensors for turbopump testing in France, monitoring fuel pressure, chamber stability, and structural response during automated firing sequences.
For non-standard configurations, STS develops customized sensor solutions in collaboration with engineering teams. Materials, ranges, output signals, and connectors can all be configured to match specific test stand requirements.
Accurate pressure data is the foundation of every reliable aerospace test campaign. Drift, thermal effects, and electronic aging are unavoidable challenges, but they can be managed through informed sensor selection, appropriate calibration practices, and drift-resistant sensor technology.
By matching sensor specifications to the exact demands of each test application, engineering teams reduce data uncertainty and avoid costly re-testing. STS Sensors brings over 35 years of Swiss-made precision to this challenge, offering modular, customizable pressure sensors that perform reliably under the conditions aerospace testing demands.
An aerospace pressure sensor converts gas or fluid pressure into an electrical signal used for monitoring and control in aircraft and spacecraft systems. These sensors must meet strict accuracy and reliability standards for safety-critical applications such as engine testing, cabin pressure regulation, and hydraulic monitoring.
Sensor drift causes measurement values to shift gradually, even when actual pressure remains constant. In aerospace testing, this can lead to incorrect data, false alarms, or missed faults. Selecting sensors with low inherent drift reduces these risks.
STS Sensors builds piezoresistive pressure sensors with factory-calibrated temperature compensation and robust, hermetically designed housings. This combination minimizes thermally and environmentally induced drift, reducing the frequency of recalibration during long test campaigns.
Ranges vary depending on the application. Cabin pressure monitoring may require sensors in the low millibar range, while propulsion and hydraulic testing can demand measurements up to several hundred bar. STS Sensors offers configurable ranges from 50 mbar to 1000 bar to cover this full spectrum.
Yes. STS Sensors designs customized sensor configurations that match specific measurement tasks. Materials, pressure ranges, output signals, and mechanical connections are all configurable. The process spans from technical analysis and prototyping through to series production.