A sensor assembly is provided that includes a frame having two or more structural supports. A coating is provided over the frame. The coating has at least one deformable region disposed between the two or more structural supports. The sensor assembly includes at least one optical component disposed within the at least one deformable region such that the at least one optical component can move relative to the two or more structural supports. 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. Methods of manufacture and use of the sensor assembly are also provided.