Hall effect-based pressure sensor using dome-annular magneto-elastomer for garment pressure measurement

Garment pressure measurement is essential for evaluating comfort, fit quality, and physiological function in both everyday clothing and specialized garments. The AMI-3037 pneumatic sensor has served as the reference standard for nearly three decades, but its high channel cost, time-consuming per-channel calibration, and temperature-dependent drift have limited broader adoption. This study introduces a Hall effect-based pressure sensor utilizing an integrated dome–annular magneto-elastomer architecture designed to overcome these constraints. The deformable magnetic composite modulates magnetic flux under applied pressure, eliminating the rigid-magnet dependency of conventional Hall-based designs. Finite element simulations confirmed that the dome–annular structure produces a stable, predominantly axial magnetic field that varies linearly with deformation, enabling predictable single-axis Hall transduction. Mechanical characterization demonstrated minimal hysteresis, high repeatability, and strong sensitivity within the garment-relevant low-pressure range. Mannequin testing across three compression-garment sizes and four curved anatomical sites showed that the sensor achieves measurement accuracy statistically equivalent to the AMI-3037 reference. The sensor maintains a 4 mm thickness profile matching the AMI-3037 form factor while offering substantial advantages: low-cost fabrication, reduced susceptibility to temperature-related pneumatic drift, conformability to curved surfaces, and elimination of repeated pre-experimental calibration. These characteristics enable practical multi-site pressure assessment previously infeasible with pneumatic systems. The sensor provides a rigorously validated alternative to pneumatic standards and establishes a foundation for next-generation garment pressure measurement in research, clinical, and industrial applications.