Capacitive probe fabricating from spray deposition

A method of mounting a proximity sensor within a gas turbine engine comprising:

• forming an opening within a case structure proximate a rotating structure;
• extending a sensor wire through the opening in the case structure;
• depositing a base non-conductive layer with a thermal spray process onto an inner surface of the case structure around the sensor wire;
• encapsulating the sensor wire within a conductive layer deposited onto the base non-conductive layer with a thermal spraying process;
• depositing a non-conductive abraidable layer over the conductive layer;
• and
• removing a portion of the abraidable layer to expose the conductive layer.

A proximity sensor comprising:

• a lead supported on an outer surface of a case structure;
• a sensor wire extending from the lead and through an opening in the case structure;
• a base non-conductive layer thermally applied to an inner surface of the case structure around the sensor wire;
• a conductive layer thermally deposited onto the base non-conductive layer and encapsulating the sensor wire;
• and
• a cover non-conductive layer thermally deposited over portions of the conductive layer such that an area of the conductive layer is exposed to define a sensor area.