Development and production of EAP-based sensor and actuator systems for robotics, infrastructure and medical technology

Delfa Systems GmbH

Neunkirchen (DE)New on Amplifa

2022Founded

GmbHLegal form

Neunkirchen (Saar)Development and production site

up to 1 µmMeasurement accuracy

< 1 mmThickness of sensor layers

About Delfa Systems

Delfa Systems GmbH develops and produces intelligent sensor and actuator systems based on electroactive polymers (EAP) and dielectric elastomers. The product portfolio comprises three modular product families: DST Stretch Systems (flexible strain sensors for motion, length change and vibration), DLO Load Systems (force and load sensors) and DFL Flex Systems (thin, adaptive actuators with tactile feedback, e.g. for level measurement, media detection and electroadhesive gripping structures). The sensor elements made of rubber-like elastomers are combined with flexible electronics on polymer substrates and FR4/flex circuit boards, achieving measurement accuracies of up to 1 µm with layer thicknesses below 1 mm. Areas of application include infrastructure monitoring (bridges, tunnels, buildings), industrial automation and robotics (e.g. 3-axis force/torque sensor for end-of-arm tooling), medical technology, micro- and optoelectronics, aerospace, wind turbines and commercial vehicles. The company manufactures standardised, configurable sensors as well as customised solutions and monitoring systems with gateway and cloud-based evaluation – development and production take place entirely in-house at the Neunkirchen site in Saarland.

Site: Neunkirchen
Processes: EAP-based sensor technology (strain, force and level sensors, adaptive gripping systems,, DST Stretch Systems – flexible strain sensors (motion detection, length change,, DLO Load Systems – force and load sensors (force, touch, pressure, smallest displacements), DFL Flex Systems – thin adaptive actuators and flexible sensor technology (level, media detection,, Development and manufacture of customised sensor and actuator systems (in-house production), 3-axis force/torque sensor (F/T sensor) for robotics, end-of-arm tooling, Customised sensor solutions, Standardised sensor products
Materials: Electroactive Polymers (EAP), Dielectric Elastomers, Rubber-based Elastomers (sensor elements), Polymer Substrates (flexible electronics), FR4 / Flex Circuit Boards (combinable), Rubber-based Elastomers, FR4 / Flex Circuit Boards
Founded: 2022
Industries: Infrastructure monitoring, Industrial automation/robotics, Medical technology and healthcare, Micro- and optoelectronics, Aerospace, Research

01
In-house sensor development
02
Manufacture of the elastomer sensor elements
03
Integration of flexible electronics
04
Assembly and testing
05
Delivery incl. cloud-based evaluation/monitoring

Materials and Processes

EAP

Electroactive Polymers (EAP)

Core technology for strain, force and level sensors as well as adaptive gripping systems with micrometre accuracy.

Dielectric Elastomers

Flexible, soft base material of the product portfolio for sensor and actuator applications.

Rubber-based Elastomers

Sensor elements of the DST and DLO systems, robust against shocks, vibrations and misalignment.

P-FLEX

Polymer Substrates (flexible electronics)

Carrier material of the DFL Flex Systems for thin, adaptive actuators and sensor technology.

FR4

FR4 / Flex Circuit Boards

Combinable circuit board technology for the intelligent sensor electronics.

Locations

Neunkirchen

Development and production site (office and production space)

Lot size: Prototype to series (customised and standardised)
Materials: EAP, dielectric elastomers, flexible electronics

Industries

Infrastructure monitoringIndustrial automation/roboticsMedical technology and healthcareMicro- and optoelectronicsAerospaceResearchWind turbinesCommercial vehicles

Processes & technical limits

Processes	Tolerance	Max. part	Weight	Lot size	Materials
EAP-based sensor technology (strain, force and level sensors, adaptive gripping systems,Testing	up to 1 µm accuracy	–	–	–	Electroactive polymers (EAP), dielectric elastomers, flexible electronics on polymer substrates
DST Stretch Systems – flexible strain sensors (motion detection, length change,Testing	up to 1 µm	–	–	–	Elastomer (rubber-based)
DLO Load Systems – force and load sensors (force, touch, pressure, smallest displacements)Testing	–	–	–	–	Elastomer
DFL Flex Systems – thin adaptive actuators and flexible sensor technology (level, media detection,Plastics	–	–	–	–	Elastomer, polymer substrates, various electrode materials
Development and manufacture of customised sensor and actuator systems (in-house production)Engineering	–	–	–	–	Electroactive polymers (EAP)
3-axis force/torque sensor (F/T sensor) for robotics, end-of-arm toolingTesting	–	Diameter 49 mm, height 20 mm	approx. 55 g	–	elastomer-based sensor element

Additional services

Customised sensor solutionsStandardised sensor productsMonitoring systems with gateway and cloud-based evaluationDevelopment and production entirely in-houseConfigurable standard sensorsAdaptive gripping systemsAir bubble detectionLevel sensors

Reference customers

Mecademic (sensor optimised on the Meca500 robot)Wacker (joint presentation of Nexipal Sense at K 2025)

History

2022
Founded as a spin-off of Saarland University under the EXIST research transfer programme
2023
Relocation to the new development and production site in Neunkirchen (September 2023)
2025
Presence at Sensor+Test 2025 in Nuremberg (real-time monitoring, multi-parameter sensor technology)
2025
Networking meeting with BVMW Rhineland-Palatinate & Saarland in Neunkirchen (June 2025)
2026
Presentation of the 3-axis force/torque sensor for robotics at all about automation in Friedrichshafen (March 2026)
2026
Presentation of new 3D sensor technology for robotics and infrastructure monitoring at Hannover Messe 2026 (April)