FAQ

A high voltage resistor is an electrical resistor specifically designed for applications involving high voltages. It is used to precisely measure, limit, divide, or safely dissipate high voltages and is characterized by its high voltage capability, long-term stability, and reliability.

High voltage resistors are used in a wide range of applications, including X-ray equipment, medical technology, measurement and test equipment, drive technology, and industrial high voltage systems.

Metallux AG has been developing and manufacturing thick-film high voltage resistors on ceramic substrates for demanding industrial applications for over 40 years. The portfolio includes both standard and custom solutions offering high precision, excellent long-term stability, and high reliability.

Development and manufacturing take place in Germany – from prototype development to series production for OEMs worldwide.

High voltage resistors from Metallux AG are characterized by reliability, precision, and a high degree of customization. Metallux develops and manufactures high voltage resistors in various designs, including flat resistors and tubular resistors, as well as custom solutions.

The portfolio includes high voltage resistors, pulse resistors, high voltage dividers, high voltage resistor networks, resistors for PCB assembly, and adjustable high voltage potentiometers. In addition to a broad range of standard products, Metallux develops customized solutions tailored precisely to the technical requirements of each application.

With decades of experience in thick-film technology, Metallux has extensive expertise in developing high voltage resistors for demanding applications. The products are used worldwide in areas including medical technology, energy technology, measurement technology, drive and automation technology, and X-ray equipment.

Leading companies worldwide rely on the quality, reliability, and durability of Metallux high voltage resistors.

Yes. High voltage resistors from Metallux AG can be customized to meet the specific requirements of each application. With decades of experience in thick-film technology, Metallux develops custom solutions for OEMs and industrial applications.

Depending on the application, the following characteristics can be customized:

• Resistance values
• Voltage ranges
• Designs and dimensions
• Connections
• Tolerances
• Protective coatings

High voltage resistors are used wherever high voltages need to be precisely measured, limited, divided, or safely dissipated. Typical industries and fields of application include medical technology, X-ray technology, test and measurement technology, energy technology, drive and automation technology, research, and industrial electronics.

Typical applications include:

• Industrial X-ray systems for detecting voids in cast components
• X-ray systems for foreign object detection in the food and beverage industry
• Defibrillators
• Insulation testing equipment
• Electrostatic precipitators
• Spectrometers
• Charging, discharging, and braking resistors in drive technology

High voltage resistors are used in X-ray technology to precisely measure, monitor, and control high voltages. They help ensure reliable and safe operation of X-ray systems while maintaining consistent performance and image quality.

Typical applications include:

• Industrial X-ray systems for detecting voids, cracks, and other defects in cast components
• X-ray inspection systems for foreign object detection in food and beverage production and filling lines
• Medical X-ray systems, including CT scanners and mammography systems
• X-ray baggage scanners at airports and other security checkpoints
• Measurement and test systems for the electrical testing of printed circuit boards (PCBs)
• Inspection systems for distinguishing between filled and empty containers

Metallux AG develops and manufactures thick-film high voltage resistors for demanding applications in X-ray technology. With decades of experience, Metallux offers both standard products and custom high voltage resistors tailored to the specific technical requirements of each X-ray application.

High voltage resistors perform important functions in drive and automation technology, particularly in the control, regulation, and protection of electrical drive systems. They are used as charging resistors, discharging resistors, and braking resistors to limit, dissipate, or safely discharge electrical energy. This helps ensure operational safety, protect electronic components, and maintain the reliable operation of drive systems.

Typical applications include:

• Hoists and chain hoists
• Industrial doors and automatic door drives
• Baggage handling and conveyor systems
• Frequency converters
• Inverters
• Spindle drives
• Capacitors and capacitor banks for safe charging and discharging

Metallux AG develops and manufactures thick-film high voltage resistors for demanding applications in drive and automation technology. In addition to a broad range of standard products, Metallux develops custom high voltage resistors tailored to the specific requirements of each application in terms of resistance value, power rating, design, and environmental conditions.

High voltage resistors are used in energy and environmental technology for voltage measurement and monitoring, power limitation, energy dissipation, and the protection of electrical and electronic components. They are particularly important in power grids, high voltage systems, transformers, and wind energy applications where high voltages must be handled safely and reliably.

Typical applications for high voltage resistors include:

• Voltage transformers and current transformers for precise voltage measurement and monitoring in power grids
• Braking resistors for wind turbines to safely dissipate electrical energy during emergency shutdowns
• High voltage dividers for voltage measurement and monitoring in transformers and high voltage systems

Metallux AG develops and manufactures thick-film high voltage resistors for demanding applications in the energy and environmental technology sector. In addition to a broad range of standard high voltage resistors, Metallux provides custom high voltage resistors tailored to specific requirements in terms of resistance value, operating voltage, power rating, dimensions, design, and environmental conditions.

The long-term stability of a high voltage resistor describes its ability to maintain a consistent resistance value and electrical characteristics over many years of operation. High long-term stability helps ensure reliable measurement results, consistent performance, and a long service life – even under continuous high voltage and demanding environmental conditions.

Long-term stability is particularly important in applications such as high voltage measurement, X-ray technology, medical technology, test and measurement equipment, and industrial high voltage systems.

High voltage resistors from Metallux AG are designed for high long-term stability through an optimized manufacturing process. They are suitable for applications that require consistently precise measurement results and high reliability over a long service life.

Different high voltage resistor technologies are available depending on the electrical and mechanical requirements of the application. Common technologies for high voltage resistors include thick-film technology, thin-film technology, wirewound resistors, and specialized film and composite technologies. Selecting the right high voltage resistor technology depends on factors such as operating voltage, power rating, resistance value, precision, temperature characteristics, and long-term stability.

Metallux AG specializes in thick-film high voltage resistors on ceramic substrates. This proven technology combines high voltage capability with excellent long-term stability, precise resistance values, and a compact design. Thick-film high voltage resistors are particularly suitable for demanding applications in X-ray equipment, medical technology, high voltage measurement, test equipment, and industrial high voltage systems.

With in-house development and manufacturing in Germany, Metallux offers a broad range of standard and custom high voltage resistors for OEM applications. Custom high voltage resistors can be tailored to specific electrical and mechanical requirements – from small production runs to high-volume series production.

The tolerances of high voltage resistors depend on the specific application and its technical requirements. Different precision and tolerance classes are available to ensure accurate resistance values and reliable performance.

Typical high voltage resistor tolerances include ±0.5%, ±1%, ±2%, ±5%, ±10%, and ±20% untrimmed. The appropriate tolerance depends on factors such as the required accuracy, long-term stability, and operating conditions of the application.

Metallux AG develops and manufactures high voltage resistors as both standard products and custom high voltage resistors for OEM applications. Depending on the requirements, resistance value, tolerance, temperature characteristics, and other electrical properties can be tailored to the specific application.

Looking for the right high voltage resistor and tolerance for your application? Contact Metallux to discuss your technical requirements.

Thick-film high voltage resistors offer a number of advantages for demanding industrial applications:

• Compact designs for space-saving integration
• High voltage capability for demanding high voltage applications
• Excellent long-term stability and reliable electrical performance
• Precise resistance values and high accuracy
• Cost-effective solutions based on proven thick-film technology
• Wide range of designs and customization options

Metallux AG has many years of experience in developing and manufacturing thick-film high voltage resistors for demanding industrial applications. In addition to a broad range of standard products, Metallux provides custom high voltage resistors tailored to the electrical, mechanical, and environmental requirements of each application.

Industrial joysticks can generally be divided into thumb, finger and hand joysticks. Metallux AG develops and manufactures all three types for a wide range of industrial applications. The most suitable joystick design depends on the control task, available installation space and required functionality.

In addition to their design, industrial joysticks differ in terms of number of axes, Hall-effect or potentiometer technology, output signals, interfaces, and mechanical and ergonomic features. The most suitable configuration depends on the specific application requirements.

Whether a Hall-effect joystick or a potentiometer joystick is the better choice depends on the requirements of the specific application. Both technologies offer distinct advantages and are developed and manufactured by Metallux AG for industrial control applications.

The main difference lies in the method of position detection: potentiometer joysticks use mechanical contact, while Hall-effect joysticks operate contactlessly using magnetic fields.

Hall-effect joysticks use a contactless Hall sensor, allowing position detection without mechanical contact. They are particularly suitable for applications requiring high measurement accuracy, digital interfaces or redundant signals. Depending on the design, analog and digital interfaces such as PWM, CAN, SPI or SAE J1939 are available.

Potentiometer joysticks detect position using proven resistive technology. They enable absolute position measurement and provide an absolute analog output signal. Another advantage is their high immunity to electromagnetic interference (EMC), making them a cost-effective and reliable solution for many industrial applications.

A particular advantage of Metallux is its in-house development and manufacturing of potentiometer technology. This allows output signals, voltage ranges, characteristic curves and other electrical properties to be flexibly adapted to specific application requirements.

Metallux AG offers industrial joysticks with both technologies and can select the most suitable sensing technology for each application.

Potentiometer joysticks detect the position of the control lever using a precision resistive element. They have proven themselves in industrial applications for decades and offer numerous advantages, particularly when absolute position measurement, high EMC immunity and a cost-effective overall solution are required.

The main advantages of potentiometer joysticks include:

Metallux AG develops and manufactures the potentiometers used in its joysticks in-house. This enables fast and flexible customization, for example of output signals and voltage ranges. The result is customized joystick solutions tailored precisely to the requirements of OEMs and machine manufacturers.

Contactless Hall-effect joysticks detect the position of the control lever using the Hall effect, without mechanical contact between the sensor and magnet. This provides numerous advantages for demanding industrial applications.

The main advantages of Hall-effect joysticks include:

Metallux AG develops and manufactures contactless Hall-effect joysticks for construction machinery, agricultural machinery, material handling equipment, cranes, municipal vehicles, radio remote controls and many other industrial applications.

Depending on the application, industrial joysticks can be designed with one, two, three or multiple axes. Single-axis joysticks control movement along one axis, while dual-axis joysticks can control movements in the X and Y directions, for example. Three-axis and multi-axis joysticks enable simultaneous or combined control of multiple functions.

Metallux AG offers single-axis, dual-axis, three-axis and multi-axis industrial joysticks in various designs and configurations. The appropriate number of axes depends on the required control functions, operating concept and specific application.

Industrial joysticks are available with various analog and digital output signals as well as communication interfaces. The most suitable configuration depends on the control system, machine architecture and specific application requirements.

Depending on the product series and configuration, Metallux AG offers industrial joysticks with the following output signals and interfaces:

Depending on the application, redundant output signals, different supply voltages and customized electrical characteristics are also available.

Redundancy in an industrial joystick means that multiple independent signals are provided for position detection. The machine control system can compare these signals to identify deviations or faults.

Redundant industrial joysticks are particularly used in applications with high safety and reliability requirements, such as construction machinery, agricultural machinery, cranes, material handling equipment, municipal vehicles and radio remote controls.

Metallux AG offers industrial joysticks with redundant output signals using both Hall-effect and potentiometer technology. Depending on the product series and application, the joysticks can be customized to meet the specific requirements of OEMs and machine manufacturers.

Industrial joysticks can be configured with various mechanical functions and features depending on the application. The appropriate configuration influences operating behavior, ergonomics and safe machine control.

Depending on the joystick series, Metallux AG offers the following options:

• Spring return to center
  When released, the joystick automatically returns to its center position by spring force.
• Spring return to end position
  In certain configurations, a spring automatically returns the joystick to a defined end position when released.
• Detent positions with spring return to center
  The joystick engages in up to five defined positions during operation and automatically returns to the center position when released.
• Detent positions with position locking
  The joystick remains in the selected detent position until it is moved again. Depending on the configuration, up to five detent positions are available.
• Friction hold (friction brake)
  The joystick remains in the selected position. Depending on the model, this configuration can also be combined with a center detent.

Depending on the application and product series, these functions can be combined with different limiters, handle shapes, handle functions, switches, pushbuttons and sensor technologies. Customer-specific adaptations to individual operating and control requirements are also possible.

Compact, precise, robust and energy-efficient industrial joysticks are particularly suitable for industrial radio remote controls. Depending on the application, finger joysticks and thumb joysticks are commonly used. The most suitable design depends on factors such as available installation space, number of axes, required functions and machine control requirements.

Metallux AG develops and manufactures industrial joysticks for radio remote controls using both Hall-effect and potentiometer technology. Potentiometer joysticks are particularly suitable for battery-powered radio remote controls due to their very low power consumption, which can contribute to longer battery life. Their operating principle also makes them highly resistant to electromagnetic interference.

Depending on the product series and application, features such as redundant output signals, detent functions, dead man's switches, LED illumination and vibration feedback are available.

Metallux joysticks are used in radio remote controls for construction machinery, cranes, forestry and agricultural machinery, material handling equipment, municipal vehicles and marine applications, among others.

Link to the application example: Gross-Funk has been using Metallux industrial joysticks in its radio remote controls for more than 15 years. The joysticks are customized to meet the requirements of each application.

Industrial joysticks are used wherever machines, vehicles and equipment need to be controlled precisely, safely and ergonomically. Typical applications include:

Metallux AG develops and manufactures industrial joysticks for a wide variety of industrial applications. Depending on the operating environment and requirements, thumb, finger and hand joysticks are available with Hall-effect or potentiometer technology and various mechanical and electrical configurations.

The most suitable joystick solution depends on factors such as installation space, operating concept, number of axes, environmental conditions and required functions.

Practical example: Our user report, featuring Gross-Funk, demonstrates how industrial joysticks from Metallux AG are used in radio remote controls. Read the user report here.

Metallux AG develops and manufactures custom industrial joysticks for OEMs, machine manufacturers and manufacturers of industrial radio remote controls.

As a manufacturer with in-house development and production capabilities and more than 25 years of experience in industrial joysticks, Metallux offers a modular product portfolio that can be flexibly adapted to different technical and functional requirements.

This enables the development of customized joystick solutions with a wide range of individually configurable features, including:

A particular advantage of Metallux AG is its in-house development and manufacturing of potentiometer technology. This allows output signals, voltage ranges, characteristic curves and other electrical properties to be adapted particularly flexibly to the requirements of each application.

Whether for construction machinery, agricultural machinery, material handling equipment, cranes, municipal vehicles or industrial radio remote controls, Metallux develops and manufactures custom industrial joysticks for a wide variety of industrial applications.

A linear sensor (also known as a linear position sensor or linear displacement sensor) is a sensor used to measure linear displacement and position. It detects the movement of an object and converts it into an electrical signal. Linear sensors are used to precisely measure and monitor positions, travel distances and linear movements.

Linear sensors are used in a wide range of industrial applications, including mechanical engineering, automation technology, medical technology, agricultural machinery, construction machinery, testing equipment, packaging machinery, conveyor systems, as well as measurement and control systems.

Metallux AG develops and manufactures potentiometric linear sensors for industrial applications. Thanks to their absolute position measurement, high linearity, EMC immunity and long service life, these sensors are particularly suitable for demanding OEM applications. Depending on the application, Metallux AG offers both standard solutions and custom linear sensors that can be individually adapted in terms of measuring range, design, output signal and mechanical configuration.

A potentiometric linear sensor detects the linear position of a moving object and converts it into an electrical signal. A wiper moves along a resistive track. As the wiper position changes, the output voltage changes accordingly, providing a distinct output signal for each position. This proven measuring principle enables precise, simple, reliable and cost-effective position measurement.

Metallux AG develops and manufactures potentiometric linear sensors for industrial applications. Thanks to absolute position measurement, the current position is available immediately after power-up – no homing procedure or initialization is required. This makes the sensors particularly suitable for demanding OEM applications in mechanical engineering and automation technology.

Different measuring ranges, designs and mechanical configurations are available depending on the application. In addition, the sensors can be customized to meet specific requirements.

Various sensor technologies are available for linear displacement measurement. These include potentiometric linear sensors, inductive linear sensors, magnetostrictive linear sensors, LVDT sensors, optical linear sensors and laser displacement sensors. The most suitable technology depends on the specific requirements of the application.

Metallux AG specializes in the development and manufacturing of potentiometric linear sensors. These are characterized by absolute position measurement, high linearity, EMC immunity, easy integration and excellent value for money. They are particularly suitable for industrial applications in mechanical engineering, automation technology, medical technology and mobile machinery.

Metallux offers linear sensors in various versions, including PCB-based sensors, potentiometers, membrane sensors and customizable potentiometer elements.

Depending on the application, Metallux AG develops standard and custom linear sensors that can be individually adapted to the requirements of OEMs and machine manufacturers in terms of measuring range, design, output signal and mechanical configuration.

A pressure measuring cell is the core measuring element of a pressure sensor. It converts pressure acting on a diaphragm into an electrical signal. This signal can then be processed by electronic circuitry for pressure measurement, monitoring or control.

Metallux piezoresistive pressure measuring cells use resistors arranged in a Wheatstone bridge circuit. When pressure is applied, the diaphragm deforms slightly, causing changes in resistance and generating a pressure-dependent electrical output signal. The Wheatstone bridge is applied using proven thick-film technology.

Metallux develops and manufactures ceramic pressure measuring cells and stainless steel pressure measuring cells for industrial applications, enabling precise pressure monitoring of gases and liquids.

A pressure measuring cell is the actual pressure-sensitive sensing element, whereas a pressure sensor or pressure transmitter typically includes additional components such as a housing, process connection and electronics.

The pressure measuring cell detects pressure and converts it into an electrical signal. It can be integrated directly into a customer's own assembly or custom-designed housing.

Pressure measuring cells are therefore particularly suitable for OEM applications requiring compact designs or application-specific integration.

Pressure measuring cells differ in terms of design, dimensions, pressure range, pressure reference type and output signal. Metallux primarily offers ceramic and stainless steel pressure measuring cells.

For ceramic pressure measuring cells, Metallux typically uses 96% alumina ceramic (Al₂O₃). This robust ceramic material is suitable for precise pressure measurement in a wide range of industrial applications. Stainless steel pressure measuring cells are particularly characterized by their high overpressure resistance, making them suitable for applications involving high pressure loads or requiring the specific material properties of stainless steel.

Depending on the design, monolithic or flush-mounted pressure measuring cells are available for different pressure types and measuring ranges, with various electrical output signals.

Depending on the design, pressure measuring cells can measure gauge pressure, absolute pressure and sealed gauge pressure.

Gauge pressure is measured relative to the current ambient atmospheric pressure.
Absolute pressure is measured relative to a vacuum.
Sealed gauge pressure is measured relative to a defined, sealed reference pressure.

The appropriate pressure measurement type depends on the specific application and environmental conditions.

Metallux offers ceramic pressure measuring cells for pressures ranging from -1 to 600 bar and stainless steel pressure measuring cells for pressures ranging from 10 to 1,000 bar.

Depending on the design, these pressure cells can measure gauge pressure, absolute pressure or sealed gauge pressure.

In a flush-mounted pressure measuring cell, the pressure-sensitive diaphragm is directly exposed to the measured medium, whereas a monolithic pressure measuring cell has a recessed diaphragm due to its design.

Flush-mounted pressure measuring cells are particularly advantageous for viscous, pasty or contaminated media, as well as media prone to deposits or build-up.
The choice of design depends on the medium, hygiene requirements, cleaning procedures and installation conditions.

Depending on the design, pressure measuring cells can provide analog or digital output signals.

Metallux offers pressure measuring cells with analog output signals, including ratiometric output signals ranging from 10% to 90% of the supply voltage, as well as versions with a digital I²C interface.

The appropriate signal type depends on the required signal processing and the specific application requirements.

The media compatibility of a pressure measuring cell primarily depends on the materials that come into contact with the measured medium.

Ceramic pressure measuring cells are suitable for a wide range of liquids and gases and offer high chemical resistance. Stainless steel pressure measuring cells can be used in applications involving acids or hydrogen, for example.

For aggressive or special media, material compatibility should always be verified for the specific application.

Ceramic pressure measuring cells combine a robust design with high chemical resistance, long-term stability and excellent measurement performance.

Ceramic is corrosion-resistant and offers high mechanical strength. Combined with thick-film technology, it enables the production of compact and reliable pressure measuring cells for industrial series applications.

Another advantage is the ability to customize the sensing element and electronics to meet specific application requirements.

The following criteria should be considered when selecting a pressure measuring cell:

Metallux supports customers in selecting the appropriate pressure measuring cell for their application and develops customized solutions.

Yes. Metallux develops and manufactures pressure measuring cells for OEM applications and adapts these products to customer-specific requirements.

The pressure range, electrical characteristics, output signal, design and other product parameters can be tailored to the requirements of the application.