Step 3: Cut sensors out of batch mat

A laser cutter can be used to cut the sensor mat into multiple sensors. The mat must be laminated with masking tape to prevent it from burning during the laser cutting process. The following table shows the power settings used for this construction method for the United Laser Systems: VLS 6.60 laser cutter brand. These settings may vary if the sensor's construction is altered. 

Various custom shapes can be cut from the sensor mats to fit numerous applications including the many differently shaped areas of the body. This flexibility allows both larger and smaller areas to be addressed, something that with other sensors might require a multi-sensor array.

The process also singes the fibers on the edges of the conductive fabric preventing shortages of the electrodes and makes the sensor more robust by preventing individual textile fibers from unraveling with repeated use.  

Cutting Sensors by Hand

The finished sensor mat can also be cut by hand if there is no laser cutter accessible. This process requires more care to ensure that no fibers are touching across the dielectric layer, causing the sensor to short circuit. 

Use very sharp scissors cut the sensor mat into the desired shape. Trim any visible fraying along the sensor's edge and use a lighter to finish the edges. The lighter will slightly melt any stray fibers that might compromise the sensor's readings and prevent fraying when the sensor is stretched.