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The electroless copper plating of textiles, which have been previously printed with a catalyst, is a promising method to selectively metallise them to produce high-reliability e-textiles, sensors and wearable electronics with wide-ranging applications in high-value sectors such as healthcare, sport, and the military. In this study, polyester textiles were ink-jet printed using differing numbers of printing cycles and printing directions with a functionalised copper–silver nanoparticle catalyst, followed by electroless copper plating. The catalyst was characterised using Transmission Electron Microscopy (TEM) and Ultraviolet/Visible (UV/Vis) spectroscopy. The electroless copper coatings were characterised by copper mass gain, visual appearance and electrical resistance in addition to their morphology and the plating coverage of the fibres using Scanning Electron Microscopy (SEM). Stiffness, laundering durability and colour fastness of the textiles were also analysed using a stiffness tester and Launder Ometer, respectively. The results indicated that in order to provide a metallised pattern with the desired conductivity, stiffness and laundering durability for e-textiles, the printing design, printing direction and the number of printing cycles of the catalyst should be carefully optimised considering the textile’s structure. Achieving a highly conductive complete copper coating, together with an almost identical and sufficiently low stiffness on both sides of the textile can be considered as useful indicators to judge the suitability of the process.

Selective metallization is a widely used procedure which is usually achieved by the metal deposition and photolithography processes. The present research outlines a possible alternative to traditional methodologies enabling decreased processing time and a more environmentally friendly approach. A gradient magnetic field is applied during catalyst deposition on a non-conductive substrate so that the subsequent metal plating occurs at the required pattern. A new type of magnetic catalyst was synthesized and used for substrate surface activation. The characterization of both the magnetic catalyst and the selectively metallized non-conductive material are presented in this work.