In today’s digital economy, industrial systems rely on data to monitor processes, anticipate risks and guide automated decisions. At the foundation of this ecosystem are sensors, the devices that convert physical signals into the data powering modern operations.
Yet sensors are vulnerable: when they drift, degrade or fail, the decisions built on their data can become unreliable, with potential operational and financial consequences.
At the University of Luxembourg, Prof. Inès Chihi and her team are addressing this challenge through the FNR-funded project 3D-ENSURE , which is developing self-healing sensors designed to improve reliability while reducing maintenance needs and operational risk.
The importance of sensors: the eyes and ears of technology
Sensors act as our technological eyes and ears. By continuously measuring parameters such as temperature or pressure, they generate data that allows systems to operate safely and efficiently across sectors ranging from energy and industrial production to healthcare and transportation. Reliable sensors enable early detection of anomalies, helping operators maintain control over complex processes and prevent disruptions.
Over the years, failures in sensing and monitoring systems have repeatedly contributed to major industrial disasters across sectors. From the Three Mile Island nuclear accident in 1979 to the BP Texas City refinery explosion in 2005, and more recent incidents such as Watson Grinding in 2020, incorrect or missing measurements have led to human casualties and billions of dollars in economic losses.
Improving the reliability and resilience of sensor technologies is therefore becoming a strategic priority for industry. This is precisely the challenge addressed by the 3D-ENSURE project, led by Prof. Inès Chihi and her team at the University of Luxembourg. She is convinced that: “Before we can trust artificial intelligence and automated decisions, I believe we must first be able to trust the sensors that generate the data.”
3D-ENSURE: towards self-healing sensors
The 3D-ENSURE project explores a new generation of sensors capable of detecting anomalies and repairing themselves without any human intervention. This approach builds on two patented innovations developed by Prof. Chihi’s team and represents an important step toward more autonomous and resilient sensing systems.
For industry, the potential impact is significant. Sensor maintenance can account for approximately 25-35% of operational maintenance costs in certain industrial environments.
Technologies that enable sensors to diagnose and repair themselves could substantially reduce maintenance requirements while improving operational reliability.
“Our vision is deeply rooted in creating sustainable and human-centric solutions. Our aim is to develop smart sensor technologies that are designed with the well-being of people and the long-term health of our planet in mind.”, explains Prof. Inès Chihi.
Industry is already showing strong interest in these developments. The next step is to bring this technology closer to market. Prof. Chihi is currently preparing the launch of a spin-off company that will focus on adapting and commercialising these self-healing sensors for industrial applications.