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Sensors
Volume 25
Issue 21
10.3390/s25216778
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This is an early access version, the complete PDF, HTML, and XML versions will be available soon.
Article

Enhancing the Performance and Reliability of an Automotive Reed Sensor Through Spring Integration and Advanced Manufacturing

by
Umar Farooq
1,2,3,*,
Valentina Bertana
1,
Sergio Ferrero
1,
Domenico Cantarelli
3,
Luca Costa
3,
Simone Bigaran
3,
Luigi Costa
3 and
Luciano Scaltrito
1,*
1
Chilab-ITEM Laboratory, Department of Applied Science and Technology (DISAT), Politecnico di Torino, Corso Duca degli Abruzzi 24, 10129 Turin, Italy
2
Department of Science and Technology Innovation (DISIT), Università del Piemonte Orientale, Viale Teresa Michel 11, 15121 Alessandria, Italy
3
R&D Innovation Department, MISTA S.p.A, Via Roma 79/A, 14040 Asti, Italy
*
Authors to whom correspondence should be addressed.
Sensors 2025, 25(21), 6778; https://doi.org/10.3390/s25216778
Submission received: 24 September 2025 / Revised: 29 October 2025 / Accepted: 31 October 2025 / Published: 5 November 2025
(This article belongs to the Section Physical Sensors)
Versions Notes

Abstract

Reed sensors play an important role in improving the safety, reliability, and efficiency of modern electric vehicles. Our study evaluates their performance by measuring the switching distance under five different configurations of a cylindrical magnet using a 3D-printed test fixture. Statistical analysis revealed that the right-shift-upward configuration yielded the best performance, significantly reducing the release distance. Building on this, a prototype housing was developed using Selective Laser Sintering with polybutylene terephthalate, and a stainless-steel spring was incorporated to enhance sensitivity and reliability. The spring integration reduced the activation distance to 2.3 mm, which is an improvement of up to 60%, and it also significantly improved the consistency of the results. These outcomes demonstrate a practical method for manufacturing more reliable reed sensors for automotive sensing technology.
Keywords: additive manufacturing; automotive reliability; magnet alignment; reed sensors; sensor reliability; switching performance additive manufacturing; automotive reliability; magnet alignment; reed sensors; sensor reliability; switching performance

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MDPI and ACS Style

Farooq, U.; Bertana, V.; Ferrero, S.; Cantarelli, D.; Costa, L.; Bigaran, S.; Costa, L.; Scaltrito, L. Enhancing the Performance and Reliability of an Automotive Reed Sensor Through Spring Integration and Advanced Manufacturing. Sensors 2025, 25, 6778. https://doi.org/10.3390/s25216778

AMA Style

Farooq U, Bertana V, Ferrero S, Cantarelli D, Costa L, Bigaran S, Costa L, Scaltrito L. Enhancing the Performance and Reliability of an Automotive Reed Sensor Through Spring Integration and Advanced Manufacturing. Sensors. 2025; 25(21):6778. https://doi.org/10.3390/s25216778

Chicago/Turabian Style

Farooq, Umar, Valentina Bertana, Sergio Ferrero, Domenico Cantarelli, Luca Costa, Simone Bigaran, Luigi Costa, and Luciano Scaltrito. 2025. "Enhancing the Performance and Reliability of an Automotive Reed Sensor Through Spring Integration and Advanced Manufacturing" Sensors 25, no. 21: 6778. https://doi.org/10.3390/s25216778

APA Style

Farooq, U., Bertana, V., Ferrero, S., Cantarelli, D., Costa, L., Bigaran, S., Costa, L., & Scaltrito, L. (2025). Enhancing the Performance and Reliability of an Automotive Reed Sensor Through Spring Integration and Advanced Manufacturing. Sensors, 25(21), 6778. https://doi.org/10.3390/s25216778

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