A sensor assembly is provided that includes a skeletal frame comprising a loop structure. The sensor assembly includes at least one physiological sensor attached to the loop structure. A coating is provided over the skeletal frame and the at least one physiological sensor to form a sensor assembly. The sensor may be placed on a patient's finger, toe, and so forth to obtain pulse oximetry or other physiological measurements. Methods of manufacturing the sensor and sensor body and of applying the sensor are also provided.