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Embroidery is often the preferred technology when rigid circuit boards need to be connected to sensors and electrodes by data transmission lines and integrated into textiles. Moreover, conventional circuit boards, like Lilypad Arduino, commonly lack softness and flexibility. One approach to overcome this drawback can be flexible sequins as a substrate carrier for circuit boards. In this paper, such an approach of the development of flexible and functional sequins and circuit boards for wearable textile applications using subtractive and additive technology is demonstrated. Applying these techniques, one-sided sequins and circuit boards are produced using wax printing and etching copper-clad foils, as well as using dual 3D printing of conventional isolating and electrically conductive materials. The resulting flexible and functional sequins are equipped with surface mounted devices, applied to textiles by an automated embroidery process and contacted with a conductive embroidery thread.

Flexible and stretchable strain sensors are an important development for measuring various movements and forces and are increasingly used in a wide range of smart textiles. For example, strain sensors can be used to measure the movements of arms, legs or individual joints. Thereby, most strain sensors are capable of detecting large movements with a high sensitivity. Very few are able to measure small movements, i.e., strains of less than 5%, with a high sensitivity, which is necessary to carry out important health measurements, such as breathing, bending, heartbeat, and vibrations. This research deals with the development of strain sensors capable of detecting strain of 1% with a high sensitivity. For this purpose, a total of six commercially available metallic yarns were coated with a carbon-containing silicone coating. The process is based on a vertical dip-coating technology with a self-printed 3D coating bath. Afterwards, the finished yarns were interlooped and stretched by 1% while electrical resistance measurements were carried out. It was shown that, although the coating reduced the overall conductivity of the yarns, it also improved their sensitivity to stress. Conclusively, highly sensitive strain sensors, designed specially for small loads, were produced by a simple coating set-up and interlooping structure of the sensory yarns, which could easily be embedded in greater textile structures for wearable electronics.

Smart textiles have properties that outperform the conventional protective and decorative function of textiles. By integrating special sensors into clothing, body functions and movements can be detected. Piezoresistive sensors measure a change in electrical resistance due to the application of force in the form of stretching, pressure or bending. In order to manufacture such sensors, conventional non-conductive textile materials need to be made conductive by finishing processes. Therefore, a non-conductive silicone monofilament was coated with a conductive carbon silicone and additional silver-containing components and investigated for its suitability as a strain sensor. The changes in electrical resistance and the gauge factor as a measure of the sensitivity of a sensor were measured and calculated. In this publication, the electrical properties of such a filament-based sensor in the context of particle composition and concentration are discussed. The electrical resistance was already significantly reduced in a first step by coating with conductive carbon silicone (145 kΩ). The addition of silver-containing components further reduced the electrical resistance in a second step. Thereby, flat flakes of silver proved to be much more effective than silver-containing particles (5 kΩ at 20% addition). The former was easier to integrate into the coating and formed contact surfaces with each other at higher concentrations. Stretching the samples increased the resistance by enlarging the distance between the conductive components. With 30% silver-coated glass flakes in the coating, the highest gauge factor of 0.33 was achieved. Consequently, the changes in electrical resistance during stretching can be exploited to detect motion and the gauge factor indicates that even small changes in strain can be detected, so the herein developed coated monofilaments are suggested for use as strain sensors. Future work includes matching the particle composition and concentration to the exact application and investigating the sensors in the field.