Strain Gauge Durability Problem:

• The optimal solution is to get more of the backed silicone strain gauges.  However these are a bit expensive ranging between $8-10 each.  If we didn’t have such excess of naked strain gauges, this might be a better option.
• Another type of strain gauge is the foil type.  This type may be worth experimenting with before the productization stage because they are much less sensitive.  With our current strain gauges, I have to turn the amplifiers almost as low as they will go in order to get a good range of force.  One potential drawback is that, although I may be able to get a better range with this type, it may come at the cost of a higher dead zone.  These are approximately $27 for 5 which is still way more expensive then using our excess supply.
• Since the main problem comes from the gold strands breaking, the most cost effective solution for more durability, is to use bondable terminal pads.  These are are essentially the same thing the backed strain gauges are attached to.  With these, I should be able to isolate the delicate parts from the strain of the heavier sensor wires, by having better anchoring points on the side of where the strain gauge is attached to the metal.  It may also be possible, to mount the gauges directly on the isolator and make a packaged gauge like the ones we have.  Doing this might also help dull the sensitivity the same way the backed ones do eliminating our potential need for foil type.
• Some documentation on these terminals can be found here: http://www.omega.com/Pressure/pdf/Bridge_Completion_Resistors_RES.pdf
• I need proper measurements to determine which ones to get. I think it should be about the same size the prepackaged ones we already have.  I don’t think having smaller spacing would be very solder friendly.

Formula for strain gauge Gauge Factor.  Just found this, might come in handy.

ΔR is the change in resistance caused by strain,

R_G is the resistance of the undeformed gauge, and

ε is strain.