battery-free sensor potting detuning Archives

Diagram of the four RF decisions an OEM has to lock in before the mechanical design freezes when embedding a battery-free sensor. Before the freeze, while it is still a drawing revision: the reader plane (where the reader sits, who holds it and how often it reads, which sets the energy budget — about 30 µW at 5 m over UHF against 10 mW at 5 cm over NFC); the RF window (metal does not pass RF, so the aperture is a mechanical decision made with the enclosure concept); the material stack (potting, paint, gaskets and distance to metal, against which the antenna must be tuned); and the end-of-line test (a fixed, repeatable read geometry that records margin rather than pass or fail). After tooling, firmware, commissioning and reader integration are still open, while aperture location and size, antenna tuning, read distance and where the sensor sits are closed, recoverable only at the price of a tool.

2026-07-272026-07-27 by Mikel Choperena

Designing a battery-free sensor into your product? The RF, enclosure and end-of-line test decisions OEMs must lock in before the mechanical design freezes.

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