Frequently Asked Questions

The full system includes:

• Dielectric Sensors

• sensXPERT Blue Box (data processor and interface)

• sensXPERT Live (real-time visualization and control interface)

• sensXPERT Hub (central cloud platform for data analysis and model training)

We support plastics and composites manufacturers in a wide range of industries, including aerospace, automotive, electronics, construction, packaging, and rubber. 

We support thermosets, elastomers, composites, and thermoplastics.

Supported processes include injection molding, compression molding, resin transfer molding, reaction injection molding (RIM), autoclave curing, and more.  Contact us to confirm compatibility with your specific process.

sensXPERT FlexCure is a contactless cure monitoring solution based on high-frequency dielectric analysis (HF-DEA). It tracks real-time material behavior without embedded sensors or coupling media and is ideal for hydrogen vessel manufacturing, aviation patch repairs, and continuous processes.

FlexCure emits high-frequency electromagnetic signals near the component. As the resin cures, its dielectric properties change. FlexCure analyzes these changes to monitor curing progress, viscosity trends, and crosslinking behavior in real time.

• Contactless monitoring through composite thicknesses up to 40 mm 

• Real-time defect detection (e.g., dry spots, air gaps) 

• Optimization of cycle times and energy consumption 

• Compliance with demanding quality standards 

• Continuous processes (e.g., extrusion) 

• Filament winding with oven curing 

• Aviation patch repairs 

FlexCure supports a wide range of composite and thermoset resins. Contact us to confirm your material compatibility.

Reach out to our team to explore how FlexCure can be integrated into your production. 
Contact us

The sensXPERT Hub is the digital center of the Insight system. It collects, stores, and visualizes process data from all connected Blue Boxes and enables global monitoring, comparison, and machine learning model retraining.

Process data is used to visualize cycle behavior, flag anomalies, and retrain predictive models to ensure they adapt to real-world production changes.

Yes. All data collected can be accessed and downloaded from your Hub account through secure dashboards.

Data is stored on the Amazon Web Services (AWS) database in the E.U., specifically in Ireland. You can find more information on our data security page.

Yes, we operate fully in accordance with GDPR and applicable data protection laws. 
Privacy policy

No. sensXPERT solutions are designed to be user-friendly and accessible. All complex AI functions operate in the background, and insights are provided through simple overviews.

sensXPERT Live is the operator interface for accessing real-time material data, such as degree of cure and crystallization progress. It enables dynamic decision-making directly at the machine. 

You can visualize live process predictions, material behavior, cycle progress, and predictive quality indicators, all from one dashboard.

Yes. With OPC UA integration, sensXPERT Live can connect to and visualize existing machine signals and cycle parameters.

The Blue Box is the industrial pc unit that collects, analyzes, and interprets machine and sensor data. It serves as the intelligent core of the Insight system.

Yes. You can integrate third-party analog sensors to extend your measurement capabilities beyond cure monitoring.

These sensors provide real-time molecular insights by measuring changes in dielectric properties during curing. They are critical for accurate in-mold material monitoring. 

Yes. Our sensors are scratch-resistant, solvent-resistant, and can withstand temperatures up to 270°C.

We offer cylindrical sensors. These sensors are mounted in molds to measure real-time material behavior during manufacturing. Our standard sensor has a diameter of 9mm. Please contact us to learn more about the technical specifications of the sensors we offer.

Yes we can! sensXPERT has developed state of the art sensors with a coating that prevents voltage shortcuts or polarization introduced by highly conductive fillers. We offer in-house material measurements to select the most appropriate sensors.

sensXPERT Insight sensors are integrated directly into the mold. Therefore, sensXPERT works with customers to select the right sensor based on material science and your process. Most sensors have a thread fit to attach them to the mold. We support customers with finding the right sensor placement and integration options for their processes.

The sensXPERT Insight sensors are connected to both the mold and the sensXPERT Blue Box via a cable. The standard cable is 3m long, but other cable lengths can be manufactured. Our customers have to modify the mold for the sensors to be inserted and maintain direct contact with the material undergoing processing.

Typically between 0.5 to 1 working day once all materials are on site.

Yes. sensXPERT solutions are designed for global deployment and can be managed remotely via the Hub.

Only if process conditions, materials, and sensor placements are identical. Otherwise, separate models are recommended to ensure accuracy.

The system can adapt through automated model retraining. Please inform your sensXPERT contact when making process changes so we can ensure optimal performance.