Cambridge Sensotec Launches SIL2-compliant Oxygen Analyser for Additive Manufacturing (AM) Safety Systems

Introducing the Rapidox OEM-SIL2: Precision Oxygen Monitoring for High-Risk AM Environments

St Ives, Cambridgeshire, UK  – Cambridge Sensotec is proud to announce the launch of the Rapidox OEM-SIL2, a high-performance zirconia oxygen analyser designed to meet SIL2 compliance under IEC 61508/61511 functional safety standards in high-demand-use applications. Specifically engineered with additive manufacturing (AM) applications in mind, this analyser provides precise, real-time oxygen monitoring within inert atmospheres; ideal for safeguarding critical processes such as powder bed fusion, metal sintering, and high-temperature build chambers.

The analyser is the result of over five years of R&D into the demands of metal AM environments, where tight oxygen control and fault-proof safety systems are essential for build quality, operator safety, and regulatory compliance.

“We’re proud to launch the new Rapidox OEM-SIL2 after many years of design and testing by our dedicated R&D team, supported by some of the very best SIL2 expert consultants in the country,” said Dr Mark Swetnam, Managing Director of Cambridge Sensotec, “This analyser represents a major step forward for Cambridge Sensotec, and we’re confident it will be a valuable asset for manufacturers requiring SIL2 compliance.”

Enhancing Process Integrity in Metal AM

Metal AM processes depend on stable, low-oxygen atmospheres to ensure product quality, prevent oxidation, and avoid powder degradation. In build chambers using argon or nitrogen, even slight deviations in O₂ levels can result in costly build failures or compromised mechanical properties.
The Rapidox OEM-SIL2 is built to mitigate these risks when operating in high-demand-use applications. It offers:

• Dual-microprocessor architecture for full SIL2 functional safety compliance
• Automatic integrity checks every 10 minutes with simulated signal testing, allowing for 24/7 operation
• Multiple alarm layers, including master alarm and relay redundancy
• Real-time digital and analogue output validation (RS232/485, 0–5V, 4–20mA)
• Zirconia sensor with custom-length cabling up to 25m and multiple mounting options
• Sensor hot-swap using pre-calibrated sensors for uninterrupted operations

Housed in a compact DIN rail enclosure, the unit is available with or without a local display and is fully optimised for seamless PLC integration. Data logging and Modbus-RTU protocols come standard.

Why SIL2 Matters in Additive Manufacturing

As metal AM adoption increases across sectors like defence, aerospace, automotive, and medical, so do the demands for fail-safe process monitoring. SIL2 compliance ensures that the analyser can reliably detect and react to faults instantaneously – critical in environments where oxygen ingress could lead to fire risk, machine shutdown, or reduced product quality.

This is particularly important in enclosed AM systems using argon blanketing or vacuum atmospheres, where the analyser may serve as part of a broader Safety Instrumented System (SIS) to protect both personnel and equipment.

Designed for Harsh Industrial Conditions

With a sensor that can operate in temperatures up to 650°C, and vacuum-compatible mounting (ISO-KF and CF fittings available), the Rapidox OEM-SIL2 is well-suited to demanding build environments. The system can also accommodate a Type K thermocouple input and dewpoint measurement of water content monitoring for advanced measurement diagnosis (non-SIL2 scope).
Whether integrated into a custom machine build or retrofitted to an existing AM platform, the analyser brings confidence, compliance, and control to safety-critical gas monitoring.

About Cambridge Sensotec

Cambridge Sensotec designs and manufactures high-precision gas analysers for industrial applications worldwide. With a strong focus on OEM integration, functional safety, and global compliance, the company supplies both portable and fixed systems for sectors including additive manufacturing, pharmaceuticals, energy, and chemical processing.

For more on the Rapidox OEM-SIL2 and its application in metal AM, visit:
https://cambridge-sensotec.co.uk/product/rapidox-2100-oem-sil2/

Media Contact:
Natasha Hall
Marketing Manager
Cambridge Sensotec
+44 (0)1480 277420
natasha@cambridge-sensotec.co.uk