MASMA · Project

Ultra-Precise Magnetic Position Sensors That Replace Expensive Optical Encoders

manufacturingPilotedTRL 7

Imagine a ruler that can measure position down to a fraction of the width of a human hair — but instead of using light, it uses magnets. Right now, if you need that kind of extreme accuracy in a factory, you're stuck buying expensive optical systems that are fragile and fussy about dust and oil. A German sensor company figured out how to get the same precision from magnetic technology, which is tougher and cheaper. They built a working prototype that can measure positions to within one to ten microns — absolute, meaning it knows exactly where it is the instant you turn it on.

By the numbers

EUR 1,942,500

EU contribution for product development

1-10 micron

Absolute position measurement accuracy

6 months

Time to market after project end

100%

Industry consortium ratio

Sole SME partner — full commercial control

The business problem

What needed solving

Manufacturers of robots, CNC machines, printers, and metrology equipment need absolute position measurement with single digit micron accuracy. Today they must use expensive, fragile optical encoders that struggle in dusty or oily factory environments. There is no cost-effective magnetic alternative on the market that delivers this level of precision with absolute (instant-on) positioning.

The solution

What was built

BOGEN built a Minimal Viable Product with TMR sensor technology and absolute position measurement, plus a Generation 1 sensing head in the target compact size. They also developed a chip-based solution for high-volume markets and a digital scale writing process for producing linear and rotary magnetic scales.

Audience

Who needs this

Industrial robot manufacturers needing sub-10-micron servo positioningCNC machine tool builders replacing optical encoders in harsh environmentsDigital printing press manufacturers requiring precise absolute carriage positioningMetrology and measurement equipment companies seeking compact, robust sensorsMotion control system integrators looking for cost-effective high-accuracy encoders

Business applications

Who can put this to work

Robotics & Automation

mid-size

Target: Industrial robot manufacturers and integrators

If you are a robotics company dealing with positioning accuracy limits in your servo systems — this project developed a modular magnetic encoder achieving single digit micron accuracy (between 1 and 10 micron). It replaces optical encoders with a more robust, cost-effective magnetic solution that handles dust, oil, and vibration in factory environments. Products were planned for availability within six months past the project end date of August 2021.

Precision Machining & CNC

mid-size

Target: CNC machine tool builders and metrology equipment manufacturers

If you are a machine tool builder struggling with encoder costs or reliability in harsh workshop conditions — this project created a magnetic absolute encoder with single digit micron accuracy and increased reading distances. The modular design supports different absolute scale patterns and multiple PLC communication protocols. BOGEN built a Generation 1 sensing head in a compact target size with TMR sensor technology.

Industrial Printing & Packaging

SME

Target: Digital printing press manufacturers and print finishing equipment makers

If you are a printing equipment manufacturer needing precise carriage or web positioning but finding optical encoders too fragile or expensive — this project delivered a minimal viable product with TMR sensing and absolute position measurement. The system offers easier installation, smaller product size, and greater design flexibility compared to existing solutions, with accuracy between 1 and 10 microns.

Frequently asked

Quick answers

What would switching to this magnetic encoder cost compared to optical alternatives?

The project does not disclose specific pricing. However, the entire business case is built on being a cost-effective alternative to optical encoders for absolute measurement in the single digit micron range. BOGEN also developed a chip-based solution specifically for high-volume markets, which typically signals aggressive cost targets.

Can this scale to high-volume production?

Yes — BOGEN specifically developed a chip-based solution designed for high-volume markets. They also created a digitally driven scale writing process for producing both linear and rotary scales with different magnetic patterns. These are manufacturing-scale investments, not lab curiosities.

What is the IP and licensing situation?

BOGEN Electronic GmbH owns the results as the sole consortium partner. Since this was funded under the EIC SME Instrument with EUR 1,942,500, BOGEN retains commercial IP rights. Any licensing or OEM arrangement would need to be negotiated directly with BOGEN.

Does this work with our existing PLC and control systems?

The objective explicitly mentions support for different protocols for different control architectures from leading PLC companies worldwide. The modular design detects different absolute scale patterns such as Pseudo Random Code or Nonius, suggesting broad compatibility with existing automation setups.

How accurate is this really, and in what conditions?

The target accuracy is between 1 and 10 microns — what BOGEN calls single digit micron accuracy. Being magnetic rather than optical, these encoders are inherently more tolerant of dust, oil, and vibration. The Generation 1 sensing head deliverable used TMR sensor technology with increased reading distances.

When can we actually buy or test this?

The project ended in August 2021, and the objective stated products would be available at the latest six months past the project end. Based on available project data, commercial availability was planned for early 2022. Current product status should be confirmed directly with BOGEN Electronic GmbH.

Consortium

Who built it

This is a single-company project: BOGEN Electronic GmbH, a German SME and recognized international leader in magnetic measurement. The 100% industry consortium with zero academic partners tells you everything — this is not a research experiment, it is a product development effort by an established manufacturer using EUR 1,942,500 in EIC SME Instrument Phase 2 funding. BOGEN used subcontractors to accelerate the shift to new MR technologies and improved scale materials. As the sole partner, BOGEN holds all commercial rights and decision-making power, which simplifies any business discussion considerably.

BOGEN ELECTRONIC GMBHCoordinator · DE

How to reach the team

BOGEN Electronic GmbH (Germany) — established magnetic encoder manufacturer, reachable through their corporate website

Order a report on this consortium See BOGEN ELECTRONIC GMBH profile →

Next steps

Talk to the team behind this work.

SciTransfer can arrange a direct introduction to BOGEN's technical team to discuss OEM integration, licensing, or custom encoder solutions for your application.

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