Master's Thesis

Pressure sensors in microfluidics

Final Thesis 19.94 MB Appendix 12.08 kB

Author of thesis: Bc. Ján Vírostko

Acad. year: 2025/2026

Supervisor: Ing. Jan Brodský, Ph.D.

Reviewer: Ludovico Migliaccio, Ph.D.

Abstract:

This master's thesis presents the design and development of a pressure sensor system for microfluidic applications based on piezoresistive strain gauges. The system integrates fabricated BF350 strain gauges housed in custom biocompatible resin 3D-printed casings, a custom two-layer PCB incorporating a 24-bit ADS131M04 delta-sigma ADC with four simultaneous Wheatstone bridge channels and a BSS138-based level shifter for commercial sensor interfacing, firmware for the Raspberry Pi Pico 2 microcontroller, and a Python desktop monitoring application with live visualisation, data recording, CSV export, and threshold alerting. Initial evaluation of in-house fabricated NiCr thin-film piezoresistors is also presented. The system was characterised across sensitivity, linearity, hysteresis, and repeatability using Boyle's law pressure references. Among fabricated sensors, the BF350-2AA assembly achieved non-linearity of 2.155\%FS, surpassing the commercial Honeywell ABP-015PG at 3.257\%FS, and hysteresis of 2.866\%FS. The results demonstrate that the developed system represents a viable low-cost alternative to commercial solutions for microfluidic pressure monitoring.

Keywords:

pressure sensor, piezoresistive effect, microfluidics, strain gauge, Wheatstone bridge, PCB design, signal processing

Date of defence

10.06.2026

Result of the defence

Defended (thesis was successfully defended)

znamkaAznamka

Grading

A

Process of defence

Student seznámil státní zkušební komisi s řešením své diplomové práce a zodpověděl otázky a připomínky oponenta. Dále odpověděl na otázky komise: Proč selhal původní plán vlastní výroby tenkých piezorezistivních vrstev? Technologické možnosti se prvně zdály dostatečné, ale v průběhu práce se ukázalo, že to nejsou. Jaké požadavky byly kladené na senzor, anebo šlo jen o to "pokusit se udělat co nejlepší senzor"? Šlo o to vyrobit levný senzor, který je snadný na použití a výrobu. Jsou parametry senzoru dostatečná? Senzor slouží jen na orientační měření a ověření funkčnosti mikrofluidických aparatur. Pro replikovatelné měření tlaku slouží drahé komerční senzory.

Language of thesis

English

Faculty

Department

Study programme

Microelectronics (MPC-MEL)

Composition of Committee

prof. Ing. Radimír Vrba, CSc. (předseda)
doc. Ing. František Urban, CSc. (místopředseda)
prof. Ing. Vladislav Musil, CSc. (člen)
RNDr. Ladislav Mareček, CSc. (člen)
doc. Ing. et Ing. Pavel Šteffan, Ph.D. (člen)
Ing. Josef Skácel, Ph.D. (člen)

Supervisor’s report
Ing. Jan Brodský, Ph.D.

During the work on his master’s thesis, Bc. Ján Vírostko showed an excellent level of independence, reliability, and technical maturity. Communication with the student was exemplary throughout the semester. He consulted the work regularly, reacted well to feedback, and was able to move the project forward even when the original experimental approach did not provide satisfactory results.
The thesis itself is based on a practically demanding task: the realization of a pressure sensor system suitable for microfluidic use. The student had to solve not only the sensing principle, but also mechanical integration, sensor contacting, electronics, firmware, software, and experimental testing. I consider this combination of tasks to be very challenging for a master’s thesis, and the student handled it very successfully.
The submitted work is logically organized and sufficiently documented. The theoretical part gives the necessary background, while the practical part clearly shows the development path from initial thin-film experiments to the final functional sensor assemblies. The resulting system was tested, evaluated, and compared with commercial pressure sensors. Importantly, the developed sensor platform has a clear practical value and is planned to be used further in microfluidic research, and potentially also for teaching and student demonstrations.
The work with literature is appropriate, and the formal level of the thesis is very good. In my opinion, the assignment was fulfilled completely. I highly appreciate both the final result and the student’s approach during the entire semester. I recommend the thesis for defence and evaluate it with grade A. Points proposed by supervisor: 100

Grade proposed by supervisor: A

Reviewer’s report
Ludovico Migliaccio, Ph.D.

The submitted master’s thesis of Bc. Ján Vírostko deals with the development of a pressure-sensor assembly for microfluidic applications. The aim of the work was to design and experimentally evaluate a pressure sensing system based on piezoresistive elements, including their integration into a custom microfluidic casing, development of the measurement electronics, characterization of sensor properties and comparison with selected commercial pressure sensors. In my opinion, all points of the assignment were fulfilled.
The main strength of the thesis is its broad practical scope. The student developed a complete pressure-sensing platform, including 3D-printed sensor casings, BF350 strain-gauge integration, custom electronics with a 24-bit ADC, Raspberry Pi Pico 2 firmware and a Python monitoring application. This demonstrates very good engineering ability and practical understanding of microfluidic pressure measurement.
The theoretical part is clearly written and provides a sufficient overview of pressure sensors, materials and fabrication methods. The practical part is very valuable, especially because it documents the development from initial NiCr thin-film piezoresistors to the final BF350-based sensor assemblies.
The experimental characterization is well performed. The student evaluated baseline noise, sensitivity, linearity, hysteresis and repeatability, and compared the fabricated sensors with commercial Honeywell and LabSmith sensors. The BF350-2AA sensor achieved the best results among the fabricated sensors and represents a promising low-cost solution for pressure monitoring in microfluidics.
From a formal point of view, the thesis is well arranged, readable and adequately illustrated. The work with literature is appropriate. Minor language and stylistic imperfections are present, but they do not reduce the technical quality of the thesis.
The main limitation is the use of manual syringe-based pressure generation, which affects repeatability and makes precise comparison of some parameters more difficult. Longer-term stability measurements would also be useful for practical application.
Overall, I consider the thesis to be very good, technically mature and practically useful. I recommend the thesis for defence and evaluate it with grade A - 96 points. Topics for thesis defence:
  1. 1. The BF350-2AA sensor assembly achieved the best performance among the fabricated sensors. What do you consider to be the main reason for this result, especially with respect to strain-gauge size, casing geometry, bonding quality and pressure transfer to the sensing element?
  2. 2. The fabricated sensors showed higher baseline noise than the commercial reference sensors. Which part of the system do you think contributes most to this noise, and how would you experimentally verify and reduce it in the next version of the sensor?
Points proposed by reviewer: 96

Grade proposed by reviewer: A

Responsibility: Mgr. et Mgr. Hana Odstrčilová