The Xu research group at ZJU is an interdisciplinary team focused on advanced manufacturing of flexible and conformal electronics for monitoring in both regular and extreme environments.
Our research mainly includes the development of innovative fabrication techniques, multifunctional devices, as well as system-level applications. Based on the principle of laser and matter interactions, we focus on manufacturing of versatile devices mainly using hybrid (ultrafast) laser processing platforms, which are endowed with multitasking features.
Kaichen Xu, Study Corresponding Author and Professor, Zhejiang University
Conventional high-temperature sensors are challenging to produce. They often require multiple material layers, lengthy sintering processes, and additional coatings to guard against heat and oxidation. In contrast, the new laser-based technique achieves all of that in a single step.
The laser briefly heats the surface, triggering crystallization that enables the material to conduct electricity and respond to temperature. Simultaneously, it forms a glass-like surface layer that naturally resists oxidation—eliminating the need for extra protective materials or fabrication steps.
The result is a sensor capable of high-accuracy, real-time temperature monitoring with long-term stability. In laboratory tests, the devices showed minimal signal drift—just 1.2 %—even after operating continuously at high temperatures for 20 hours.
Because the method is fast and material-efficient, it could streamline the integration of sensors directly into components like engine housings or gas pipelines, allowing engineers to detect early signs of overheating, stress, or failure more effectively.
The team is now working to extend the approach for measuring other physical variables such as pressure, strain, and heat flux, on the same thin-film platform. Their broader aim is to develop smart sensor systems capable of withstanding and performing in some of the most demanding environments, both on Earth and in space.
Journal Reference:
Hou, Y., et al. (2025) A laser-induced wide-range thin-film temperature sensor without additional anti-oxidative encapsulations. International Journal of Extreme Manufacturing. doi.org/10.1088/2631-7990/adefa2.