Patent ID: 7245459

Claim:
A method of critically exposed lapping of sensors for improved signal output, the method comprising: (a) fabricating a sensor with an axial direction, and an initial length extending in the axial direction that is longer than an operating length of the sensor; (b) forming the sensor in a structure having conductive leads that extend in the axial direction from the sensor; (c) providing an in-line lapping guide in the structure that extends in the axial direction, and a cavity material between the in-line lapping guide and the sensor such that the sensor is embedded in the structure; (d) lapping the in-line lapping guide and then the cavity material in the axial direction and monitoring an electrical resistance of the structure via the conductive leads; (e) lapping the cavity material and the sensor in the axial direction such that the initial length of the sensor is reduced to approximately the operating length of the sensor by detecting a change in electrical resistance as the sensor is lapped.