Custom Sensor Solutions Tailored to Your Application

At SST Sensing, we manufacture one of the world’s widest ranges of optical liquid level sensors, from simple, low-cost devices to highly robust solutions engineered for extreme environments. However, off-the-shelf sensors cannot meet the precise integration requirements in many real-world applications.

Our range of sensors offers extensive customisation options across different technologies. Optical Liquid Level Sensors sensors can be tailored with specific cable lengths, connectors, or housings to fit OEM systems or harsh environments. Zirconia Oxygen Sensors can be customised with modified housings, protective coatings, or specialised electronics to withstand corrosive, high-temperature, or high-humidity applications. LuminOx Optical Oxygen Sensors allow adjustments to full-scale ranges, output configurations, and firmware to meet precise measurement requirements in industrial, food, or laboratory processes. These flexible options ensure that each sensor can be optimised to the exact needs of the customer’s application.

Common challenges include mismatched wire lengths that complicate routing and housings that do not align with mechanical interfaces. These connectors fail to mate with existing electronics or firmware that requires modification to operate reliably under dynamic fluid conditions such as turbulence, entrained bubbles, or condensation. Without the right fit, these issues can lead to production inefficiencies, additional rework, and reduced confidence in long-term measurement reliability.

Tailored Sensor Solutions for Every Application

Our engineering team offers comprehensive customisation services, from simple adjustments like cable lengths or connector types to full-scale housings, electronics, and firmware redesigns. By adapting sensors to the precise requirements of OEMs and system integrators, we simplify assembly, reduce installation errors, and ensure consistent, reliable performance even in demanding operational environments. Each customised solution is engineered to integrate seamlessly into your system, providing long-term durability and optimal functionality without additional modification.

Customisation examples include:

Water Ingress / Leak Detection Sensor Application: Detects unwanted liquid ingress within critical enclosures. Environment: Installed inside server cooling system frames to identify coolant leaks and protect sensitive equipment. Connector & Output: Supplied with flying leads for screw terminal connection; 90° wire exit minimises space. Provides a high-level alarm signal on fluid detection. Custom Housing / Electronics: Low-profile M12 x 1-8g Polysulfone housing rated -25 °C to +80 °C, with LLC100D3SH Type 1 side-exit design for compact integration.

Level Switch for Diesel Filter Bowl Application: Used in diesel condensate traps on CNG-powered vehicles to detect high diesel levels, prompting emptying of the filter bowl at the next service interval. Environment: Designed for exposure to diesel fuel, high vibration, and pressures exceeding 120 bar. Connector & Output: ISO 15170 3-pin automotive connector with PWM output, including a failsafe option to indicate sensor or cable failure. Electrical Protection: Features transient over-voltage protection and short-circuit protected output. Custom Housing: M14 x 1.5 threaded 303 stainless steel body with a robust polysulfone tip.

Optimising Performance with Custom Sensors

Custom sensor solutions bring measurable benefits across industries where reliability, safety, and efficiency are non-negotiable. They are particularly valuable for:

Conclusion

Choosing a customised sensor from SST Sensing means getting a solution engineered to fit your application from the start. Whether you need adjustments to wiring, connectors, housings, or firmware or a fully bespoke design for extreme conditions, our team delivers sensors that integrate seamlessly, perform reliably, and reduce assembly and maintenance challenges.