Practical wearable e‐textiles must be durable and retain, as far as possible, the textile properties such as drape, feel, lightweight, breathability, and washability that make fabrics suitable for clothing. Early e‐textile garments were realized by inserting standard portable electronic devices into bespoke pockets and arranging interconnects and cabling across the garment. In these examples, the textile merely served as a vehicle to house the electronics and had no inherent electronic functionality. A reduction in electronic component size, the development of flexible circuits, and the ability to weave robust interconnects offer the potential for improved levels of electronic integration within the textile. The weaving of electronic circuit filaments less than 2 mm wide into fabrics such that the electronics are fully concealed in the textile and given extra protection by the surrounding textile fibers is introduced. The failure mechanisms for different filament circuit designs before and after integration into the textile are investigated with a 90° cyclical bending test. Results show that encapsulated filament circuits embedded within the textile survive 45 washing cycles and more than 1500 cycles of 90° bending around a bending radius of 10 mm, performing five times better than equivalent filament circuits before integration into the fabric.

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This paper details the design, fabrication and testing of flexible textile-concealed Radio Frequency Identification (RFID) tags for wearable applications in a smart city/smart building environment. The proposed tag designs aim to reduce the overall footprint, enabling textile integration whilst maintaining the read range. The proposed RFID filament is less than 3.5 mm in width and 100 mm in length. The tag is based on an electrically small (0.0033 λ 2 ) high-impedance planar dipole antenna with a tuning loop, maintaining a reflection coefficient less than −21 dB at 915 MHz, when matched to a commercial RFID chip mounted alongside the antenna. The antenna strip and the RFID chip are then encapsulated and integrated in a standard woven textile for wearable applications. The flexible antenna filament demonstrates a 1.8 dBi gain which shows a close agreement with the analytically calculated and numerically simulated gains. The range of the fabricated tags has been measured and a maximum read range of 8.2 m was recorded at 868 MHz Moreover, the tag’s maximum calculated range at 915 MHz is 18 m, which is much longer than the commercially available laundry tags of larger length and width, such as Invengo RFID tags. The reliability of the proposed RFID tags has been investigated using a series of tests replicating textile-based use case scenarios which demonstrates its suitability for practical deployment. Washing tests have shown that the textile-integrated encapsulated tags can be read after over 32 washing cycles, and that multiple tags can be read simultaneously while being washed.

Electronically active yarn (E-yarn) pioneered by the Advanced Textiles Research Group of Nottingham Trent University contains a fine conductive copper wire soldered onto a package die, micro-electro-mechanical systems device or flexible circuit. The die or circuit is then held within a protective polymer packaging (micro-pod) and the ensemble is inserted into a textile sheath, forming a flexible yarn with electronic functionality such as sensing or illumination. It is vital to be able to wash E-yarns, so that the textiles into which they are incorporated can be treated as normal consumer products. The wash durability of E-yarns is summarized in this publication. Wash tests followed a modified version of BS EN ISO 6330:2012 procedure 4N. It was observed that E-yarns containing only a fine multi-strand copper wire survived 25 cycles of machine washing and line drying; and between 5 and 15 cycles of machine washing followed by tumble-drying. Four out of five temperature sensing E-yarns (crafted with thermistors) and single pairs of LEDs within E-yarns functioned correctly after 25 cycles of machine washing and line drying. E-yarns that required larger micro-pods (i.e., 4 mm diameter or 9 mm length) were less resilient to washing. Only one out of five acoustic sensing E-yarns (4 mm diameter micro-pod) operated correctly after 20 cycles of washing with either line drying or tumble-drying. Creating an E-yarn with an embedded flexible circuit populated with components also required a relatively large micro-pod (diameter 0.93 mm, length 9.23 mm). Only one embedded circuit functioned after 25 cycles of washing and line drying. The tests showed that E-yarns are suitable for inclusion in textiles that require washing, with some limitations when larger micro-pods were used. Reduction in the circuit’s size and therefore the size of the micro-pod, may increase wash resilience.

Wearable devices are ideal for personalized electronic applications in several domains such as healthcare, entertainment, sports and military. Although wearable technology is a growing market, current wearable devices are predominantly battery powered accessory devices, whose form factors also preclude them from utilizing the large area of the human body for spatiotemporal sensing or energy harvesting from body movements. E-textiles provide an opportunity to expand on current wearables to enable such applications via the larger surface area offered by garments, but consumer devices have been few and far between because of the inherent challenges in replicating traditional manufacturing technologies (that have enabled these wearable accessories) on textiles. Also, the powering of e-textile devices with battery energy like in wearable accessories, has proven incompatible with textile requirements for flexibility and washing. Although current e-textile research has shown advances in materials, new processing techniques, and one-off e-textile prototype devices, the pathway to industry scale commercialization is still uncertain. This paper reports the progress on the current technologies enabling the fabrication of e-textile devices and their power supplies including textile-based energy harvesters, energy storage mechanisms, and wireless power transfer solutions. It identifies factors that limit the adoption of current reported fabrication processes and devices in the industry for mass-market commercialization. INDEX TERMSWearables, e-textile devices, e-textile power sources, e-textile manufacturing and scalability.