The paper parametrically explores the design sensitivity of a fiber optic pressure sensor (FOPS), based on the potential
failure mechanisms expected in the sensor diaphragm. The product under study is a miniature FOPS that can be
embedded in, or installed on, a structure for pressure monitoring applications. The field operating conditions are defined
in terms of temperature, pressure, and vibration loading. The FOPS probe has a Fabry-Perot cavity, with the fiber tip and
a miniature diaphragm acting as the two mirrors. The cavity length changes when the diaphragm deflects under
pressure. However, due to field operating conditions, several failure mechanisms may affect the structural and optical
characteristics of the sensor, such as cracks in the diaphragm and/or high residual stresses in the optical fiber. With the
aid of finite element analysis, this article investigates conflicting design constraints due to structural failure mechanisms
in the diaphragm and elaborates on the severity of each one by parametric design sensitivity studies.
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