Sweatlabs: Inside CORE’s Production Laboratory in Zürich, Switzerland

The gold standard of core temperature monitoring was invasive, internal measuring. CORE challenged that with the world's first and only continuous, non-invasive, and accurate core temperature monitoring solution. The secret is CORE's proprietary heat flux sensor, manufactured in the CORE production laboratory in Zürich, Switzerland.

These highly precise, 2mm heat flux sensors work by measuring the rate of heat transfer per unit area, or how much heat is flowing through the surface of the sensor. It works by converting a temperature difference into an electrical signal using a well-known physical principle. That signal, along with skin temp and heart rate, are combined through a proprietary algorithm developed and refined by the CORE team over many years to calculate the user's core temp in real-time.

But how does something so compact deliver such reliable data?

Let’s take a look behind the scenes at how these sensors are made in CORE’s production laboratory in Zürich, Switzerland.

Precision, the Swiss Way

To produce sensors that meet the demands of elite sport, workplace safety, and laboratory research, the CORE team relies on a multi-step manufacturing process defined by extreme precision. Each batch begins with a thin, flexible base material, which undergoes a tightly controlled series of steps to form sensors that are both compact and highly accurate.

To put this into perspective, some of the sensor’s internal features are measured in microns, thinner than a human hair. At this scale, precision is everything.

The process starts by drilling microscopic holes into the base material, forming the foundation of the sensor’s internal structure. Specialized materials are then deposited into the drilled holes, forming the core thermoelectric pillars that enable temperature sensing.

Between each step, the sensors are carefully cleaned to maintain purity and prevent even the smallest imperfections.

Additionally, each sensor is continuously inspected using automated imaging systems that can detect even microscopic defects. If something isn’t right, it’s caught early. By the time a sensor is finished, it has already passed multiple layers of quality control.

This level of detail is what allows CORE sensors to deliver consistent, reliable data, even in demanding conditions.

Every Sensor Is Individually Tested

Before it ever reaches you, every single CORE heat flux sensor is:

  • Measured for sensitivity
  • Tested for electrical performance
  • Calibrated for accuracy

All of this data is recorded and stored, meaning each sensor has its own unique performance profile.

In other words, no two sensors are treated as identical. Each one is verified to meet CORE’s standards.

Why This Matters for You

At the end of the day, all of this complexity serves a simple goal: giving you data you can trust.

When you're tracking a heat session or pacing in the heat, small inaccuracies can lead to big mistakes. That’s why CORE invests so heavily in how each sensor is made.

Because better data leads to better decisions and better performance.



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