A sensor assembly is provided that includes a frame having a first portion and a second portion connected by a hinge. An emitter and a detector are disposed on the frame. A coating is provided over the frame, the emitter and the detector to form a unitary sensor assembly. The sensor assembly also includes a resistance-providing component disposed generally about the hinge. In one embodiment, the sensor assembly may be placed on a patient's finger, toe, ear, and so forth to obtain pulse oximetry or other physiological measurements. A method of manufacturing the sensor assembly is also provided as is a method of cleaning a fluid-tight sensor assembly.