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The polymer core of each filament is typically made out of Kevlar or Zylon, while the surrounding coating is silver. Tens or even hundreds of these filaments are then twisted together to form a single e-thread that’s usually less than half a millimeter across. These e-threads can be easily used with common commercial embroidery equipment – the same computer-connected stitching machines that people use every day to put their names on sports jackets and sweatshirts. The embroidered antennas are lightweight and just as good as their rigid copper counterparts, and can be as intricate as state-of-the-art printed circuit boards . Our e-thread antennas can even be combined with regular threads in more complex designs, like integrating antennas into corporate logos or other designs. We’ve been able to embroider antennas on fabrics as thin as organza and as thick as Kevlar. Once embroidered, the wires can be connected to sensors and batteries by traditional soldering or flexible interconnections that plug components together. So far, we’ve been able to create smart hats that read deep brain signals for patients with Parkinson’s or epilepsy. We have embroidered T-shirts with antennas that extend the range of Wi-Fi signals to the wearer’s mobile phone.
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Textile Testing
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