In view of additive manufacturing and customized solutions, this paper describes the development of force sensors by combining DLP-printed components with shape memory alloys. The focus is on material investigations followed by FEM analysis for the development of topology-optimized carriers. By integrating shape memory wires, the sensor effect can be exploited. On the basis of two structures, the implementation is tested in practice. Two different materials are used to check the reproducibility of the results. Both materials are synthetic resins that cure under UV light. Through the practical tests, the targetperformance comparison shows the feasibility of the experiments and thus the possibility of using the developed sensors for motion monitoring. With the fusion of 3D printing, topology optimization and shape memory technology, the advantages of weight reduction, durability and the realization of individual solutions are combined.

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