Metal chip sensors have become an important means of health status monitoring and fault diagnosis of mechanical equipment.The structural metal chip sensor has the advantages of simple structure and strong adsorption of magnetic particles.However,due to the influence of environmental pressure and temperature changes,the output end of the sensor connector is prone to leakage.Reasons which cause failure of sensor are analyzed and the design of the sensor is improved by using glass sintering method to realize connection of outer shell and pin materials.The scheme is verified to be feasible,the performance of product is reliable,and it can achieve the monitoring function of metal chips.