The growing use of sub-milliohm chip resistors for current sensing creates a spectrum of challenges for the designer and the process engineer. The component format should first be selected to support the chosen thermal-management approach, with metal-element flat chip resistors having two terminals being the most cost-effective solution.
It’s then essential to design the PCB tracks and pads to meet the needs of Kelvin connection, heat dissipation, and avoidance of induced noise.