A new two-dimensional wireless and passive stress sensor using the inverse magnetostrictive effect is proposed, designed, analyzed, fabricated, and tested in this work. Three pieces of magnetostrictive material are bonded on the surface of a smart elastomer structure base to form the sensor. Using the external load, an amplitude change in the higher-order harmonic signal of the magnetic material is detected (as a result of the passive variation of the magnetic permeability wirelessly). The finite element method (FEM) is used to accomplish the design and analysis process. The strain-sensitive regions of the tension and torque are distributed at different locations, following the FEM analysis. After the fabrication of a sensor prototype, the mechanical output performance is measured. The effective measurement range is 0–40 N and 0–4 N·M under tension and torque, respectively. Finally, the error of the sensor after calibration and decoupling for Fx is 3.4% and for Tx is 4.2% under a compound test load (35 N and 3.5 N·M). The proposed sensor exhibits the merits of being passive and wireless, and has an ingenious structure. This passive and wireless sensor is useful for the long-term detection of mechanical loading within a moving object, and can even potentially be used for tracing dangerous overloads and for preventing implant failures by monitoring the deformation of implants in the human body.
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