Thin-Film Sensors for Industry 4.0: Photonic, Functional, and Hybrid Photonic-Functional Approaches to Industrial Monitoring

The transition toward Industry 4.0 requires advanced sensing platforms capable of delivering real-time, high-fidelity data under extreme industrial conditions. Thin-film sensors, leveraging both photonic and functional approaches, are emerging as key enablers of this transformation. By exploiting optical phenomena such as Fabry–Pérot interference, guided-mode resonance, plasmonics, and photonic crystal effects, thin-film photonic devices provide highly sensitive, electromagnetic interference-immune, and remotely interrogated solutions for monitoring temperature, strain, and chemical environments. Complementarily, functional thin films including oxide-based chemiresistors, nanoparticle coatings, and flexible electronic skins extend sensing capabilities to diverse industrial contexts, from hazardous gas detection to structural health monitoring. This review surveys the fundamental optical principles, material platforms, and deposition strategies that underpin thin-film sensors, emphasizing advances in nanostructured oxides, 2D materials, hybrid perovskites, and additive manufacturing methods. Application-focused sections highlight their deployment in temperature and stress monitoring, chemical leakage detection, and industrial safety. Integration into Internet of Things (IoT) networks, cyber-physical systems, and photonic integrated circuits is examined, alongside challenges related to durability, reproducibility, and packaging. Future directions point to AI-driven signal processing, flexible and printable architectures, and autonomous self-calibration. Together, these developments position thin-film sensors as foundational technologies for intelligent, resilient, and adaptive manufacturing in Industry 4.0.