Aerospace pressure sensors: Precision for critical aircraft systems

In modern aviation, the demand for accurate, reliable data has never been greater. Aerospace pressure sensors play an essential role in ensuring aircraft can operate safely, efficiently and consistently in some of the harshest environments imaginable. From monitoring hydraulic systems to supporting environmental control units, these sensors enable aircraft to function as designed, while helping engineers and operators maintain the highest standards of performance. At ESI Technology, decades of expertise in high-precision pressure measurement have positioned us as a trusted supplier to the aerospace sector.

Aerospace platforms rely on many interconnected subsystems, all of which must remain stable under extreme conditions. Temperature fluctuations, vibration, pressure spikes and corrosive media can all compromise standard components, which is why aerospace pressure sensors must be designed to withstand such challenges while continuing to deliver accurate measurements. ESI Technology’s products combine advanced sensor technology with rugged construction, making them well suited for both commercial and defence aviation applications.

Aerospace pressure sensors for fuel and hydraulic systems

Fuel and hydraulic systems are among the most safety-critical areas on any aircraft. They depend on continuous, real-time pressure monitoring to ensure smooth operation during take-off, flight and landing. Disruptions in these systems can affect everything from flight control surfaces to landing gear deployment, making precise pressure readings essential. Aerospace pressure sensors designed for these environments must offer excellent stability across wide temperature ranges and be resistant to shock and vibration. ESI Technology’s Silicon-on-Sapphire (SoS) sensor technology is particularly effective here, providing outstanding accuracy and repeatability, even when subjected to demanding operational conditions.

Hydraulic systems also operate under high loads and varying pressures, so sensors need to respond quickly to fluctuations without drifting over time. The robustness of SoS technology ensures minimal hysteresis and long-term stability, helping engineers maintain confidence in the data that keeps aircraft operating safely.

Aerospace pressure sensors in environmental and cabin control

Cabin pressurisation, air filtration and temperature regulation all depend on accurate pressure measurement. A failure in any part of an aircraft’s environmental control system can affect passenger safety and comfort, as well as the performance of sensitive onboard electronics. Aerospace pressure sensors used in this area must be capable of detecting very small changes in pressure while remaining durable enough to perform reliably over long service intervals.

ESI Technology’s high-accuracy transmitters are designed with stringent quality and testing processes to ensure they meet these requirements. The combination of advanced electronics and precise sensing elements provides aircraft manufacturers with a dependable solution for monitoring cabin and environmental pressures. This contributes to more efficient system performance, reduced operational costs and enhanced regulatory compliance.

Aerospace pressure sensors for testing and calibration

Before any aircraft enters service, every system must be validated through rigorous testing and calibration processes. High-precision measurement is vital during component development, certification testing and ongoing maintenance tasks. Aerospace pressure sensors used in these scenarios must offer exceptional accuracy and repeatability to ensure results are reliable and traceable.

ESI Technology supplies a wide range of high-accuracy pressure transmitters specifically tailored to testing and calibration environments. By incorporating Silicon-on-Sapphire technology and advanced digital electronics, these sensors support precise measurement across a broad pressure range. Their stability and minimal drift are particularly valuable when performing long-duration tests or calibrating critical systems such as engines, pneumatic controls and hydraulic assemblies.

Custom solutions for specialised aerospace applications

While many aerospace requirements can be met by standard sensor models, certain programmes and platforms demand bespoke solutions. These may involve unique pressure ranges, specialised materials, compact form factors or interface requirements not commonly available. ESI Technology offers a custom design service that enables engineers to work directly with our development team to create tailored pressure transmitters and transducers for highly specific applications.

Using a combination of advanced manufacturing methods, robust materials such as titanium and sapphire, and flexible electrical output options, these custom aerospace pressure sensors can be designed to integrate seamlessly with existing or newly developed systems. This ensures that even the most challenging requirements can be met without compromising accuracy, durability or compliance.

Built for the highest standards of performance

Aviation is a sector that demands absolute certainty, and this places significant responsibility on every component used in an aircraft. With AS9100D certification, ESI Technology demonstrates its commitment to consistently meeting the stringent quality and traceability standards required in aerospace manufacturing. Each pressure transmitter undergoes a thorough testing and inspection process to ensure it can operate in the toughest environments and deliver accurate, stable performance over its lifetime.

Aerospace pressure sensors must do more than simply measure pressure; they must be capable of operating without failure throughout long missions, extreme weather conditions and repeated thermal cycles. The durability and precision of SoS technology, combined with our extensive range of specialised and custom-built sensors, reflect ESI Technology’s dedication to meeting these challenges head-on.

As aircraft become more sophisticated and the demand for higher efficiency and safety continues to grow, the importance of reliable pressure measurement will only increase. By providing robust, accurate and meticulously engineered pressure sensors, ESI Technology supports aircraft manufacturers, maintenance teams and system designers in creating safer and more efficient aviation systems.

If you would like to explore our aerospace-ready pressure transmitters and transducers or discuss a bespoke solution for your next project, our team is ready to help.