What Really Matters for Force and Torque Sensing in Medical Robotics
Dr. Sebastian Matich, Technical Director at Resense, and Alexander Will, Head of Sensor Technologies at WIKA discussing the current development status of Resense Force/Torque Sensors.
What does it take to bring force and torque sensing into surgical robotics? And how do system requirements, integration constraints, and clinical applications come together in practice?
Drawing on experience in surgical robotics and sensor development, this article highlights the key factors behind integrating miniature 6-axis force/torque sensors into modern robotic systems.
1. Understanding Clinical and System Requirements
Successful force and torque sensing starts with understanding the surgical workflow and the robotic system as a whole. While surgical robots provide precise information about position and motion, reliably measuring interaction forces at the instrument tip remains a challenge.
Early sensor concepts from Resense were therefore developed to capture force and torque data directly at relevant interaction points during the dissertation of the Technical Director, Dr. Sebastian Matich. The goal was to create compact, accurate sensing solutions that support force feedback and provide valuable data for robotic control.
2. Compact, Precise, and Modular Sensor Design
Miniature 6-axis force/torque sensors enable integration into surgical instruments and other highly space-constrained areas where conventional sensors cannot be used.
A key element is its modular design. The sensors are based on generic elementary cells containing silicon strain gauges. This modular approach enables flexible adaptation to different system and application requirements while maintaining consistent performance.
Manufacturing at Resense is based on planar processes, enabling automation of key production steps. Performing these processes in a cleanroom environment ensures process stability and reliable sensor performance.
Combined with scalable manufacturing processes, this approach supports both customized developments and future high-volume production.
3. Integrating Sensors into Robotic Systems
In surgical robotics, sensing is most effective when it is integrated into the overall system architecture. Requirements such as sterilizability, limited installation space, and high mechanical loads make application-specific sensor integration essential.
In surgical robotics, force and torque sensing is closely linked to the overall system. Its implementation depends on the mechanical, electrical, and software architecture of the system and the specific requirements of the surgical application.
Customization in this context means integrating sensing directly into the system architecture, whether in surgical tools, interfaces, or system-specific integration points. Combining a modular architecture with compact design and high precision enables customized sensing solutions for a wide range of surgical robotic systems and application scenarios.
Customization becomes especially important for surgical instrument integrations. In these applications, sensing solutions need to address demanding requirements such as sterilizability, high axial force loads, and compatibility with scalable manufacturing processes, while fitting into highly constrained spaces and maintaining reliable performance.
The value of integrated sensing extends beyond force feedback. Reliable interaction data can support system control, tool interaction analysis, and the development of advanced robotic functionalities. By capturing data directly at relevant points within the system, sensing becomes an integral part of the overall robotic architecture. This can enable more intuitive instrument control and improved situational awareness for surgeons, while supporting controlled tissue interaction and enhanced system performance. At the same time, system providers gain access to valuable data that can be used to refine system performance and unlock new robotic capabilities.
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Learn more about our latest article on shaft-integrated force sensing and force feedback in surgical robotics: Enabling Force Feedback from the Tool Tip – Resense
