Machine-Stitched E-textile Stretch Sensors

Truly wearable sensing poses challenges in many areas. To be successful, wearable sensors must preserve wearer comfort while providing accurate sensor data. Further, for widespread commercial production they must also be compatible with soft goods manufacturing. Here, we present a method of fabricating stretch sensors using common apparel sewing machinery. The response of sensors made using industrial coverstitch (two varieties) and overlock machines are compared, and the sensor response of a bottom-thread coverstitch is characterized in depth. Three conductive thread structures are compared in the bottom-thread coverstitch sensor. Results show a consistent and repeatable response for 4and 5-ply threads, while 2-ply thread displayed more noise and less repeatability. Finally, this sensor is applied in a spinal goniometry application in three garment structures, and sensor performance is compared to motion capture data. The fabrication approach is promising for wearable sensing applications due to its manufacturability and comfort. Copyright © 2016 IFSA Publishing, S. L.