Accurate flow sensing plays a crucial role in numerous fields such as industrial automation, environmental monitoring, and biomedical engineering. In these domains, precise quantification and analysis of fluid dynamics are essential for optimizing sys...
Accurate flow sensing plays a crucial role in numerous fields such as industrial automation, environmental monitoring, and biomedical engineering. In these domains, precise quantification and analysis of fluid dynamics are essential for optimizing system performance and ensuring reliable operation. Nevertheless, traditional flow sensing devices typically exhibit large form factors and intricate structural designs, which can cause notable disturbances in the fluid stream and impede seamless integration. To overcome these challenges, we propose an innovative monolithic asymmetric thermal flow sensor (MATFS), which is manufactured by selective sintering and reduction of NiO nanoparticles triggered by laser irradiation. This approach enables the monolithic integration of a circular-heater and spiral-structured temperature sensing elements within a thin-film architecture, thereby minimizing flow disturbance and enhancing the precision of thermal measurements. In contrast to traditional calorimetric flow sensors that depend on intricate multi-electrode configurations, the proposed design employs an asymmetrically patterned spiral temperature sensor encircling the circular-heater. This compact yet refined hardware architecture not only streamlines the fabrication procedure but also establishes a fundamental platform for deep learning–driven flow estimation. By integrating the asymmetric thermal flow sensor configuration with reinforcement learning techniques, the proposed system enables precise flow vector estimation through real-time evaluation of resistance variations. The direction of fluid flow was classified with an accuracy of 96%, while the velocity was estimated with 100% accuracy. Furthermore, the sensor integrates a wireless communication module for real-time data transmission, enhancing its utility in remote and embedded monitoring applications. The resulting platform provides a compact, intelligent, and reliable solution for diverse flow estimation tasks, establishing a promising framework for next-generation smart sensing systems.