Dec 8, 20243 min read

Introduction to E-Textiles: Circuit Embroidery

By Rodney Trusty

What are e-Textiles?

E-Textiles are electronics in textiles.

What E-Textiles mean for the electronics engineer

E-Textiles are like an unlockable area in a game you’re already playing. They are an expansion of electronics engineering, so there is a call for electronics engineers to get involved. Some engineering problems are best solved with soft circuits, making e-textiles a powerful tool for the modern engineer.

What E-Textiles mean for humanity

To understand what e-textiles might mean for humanity, it helps to reflect on what PCBs have already done. Before PCBs, circuits were tangled webs of wires, chaotic and complex, like the wiring inside a 1950s TV. The invention of the PCB brought clarity and precision, organizing those wires onto thin, structured boards. This quiet revolution eventually gave us flat-screen TVs and, later, innovations like the Sphere.

It’s a simple analogy, but it shows how PCBs reshaped our technological landscape in ways no one could have fully anticipated at the time. With hindsight, we can see how profound that change was—and wonder what similar transformations e-textiles might bring.

A glimpse into the future

On the left, you see a glove designed by the University of California that tracks hand movements and translates them into sign language. In the middle is a glove I designed using Digital Fiber Studio, capable of achieving the same functionality. Unlike the university’s glove, it has no bulky wires or batteries, takes very little time to make, and is remarkably cost-effective.

This isn’t a criticism of their great work but rather a reflection on how far e-textiles have come. Just as PCBs evolved from their early beginnings to transform electronics, it’s reasonable to believe that innovation in e-textiles will follow the same path.

Advantages of E-Textiles

Sometimes, a circuit is best designed to be rigid; other times, it’s better for it to be soft. Understanding the difference is essential for electronics engineers. By learning the advantages and limitations of soft circuits, you can make informed decisions about when and how to integrate them into your designs. I will cover a few of these advantages. Think of ways a circuit can benefit from being a textile.

Flexibility

You might consider e-textiles if your circuit requires extreme flexibility, form, and fit. The image on the left shows a biometric sleeve designed by Nextiles, while the one on the right is a biometric sleeve I created in Digital Fiber Studio. These circuits take full advantage of being stretchable and flexible, allowing them to monitor the human body in ways a PCB never could. This is an example of how a circuit can benefit from the properties of a textile.

Massive Engineering Canvas

Textile circuits can cover large areas without a significant increase in manufacturing effort. Combined with their flexibility, they can access applications that PCBs cannot easily serve. For example, they are ideal for pipe covers, scaffolding wraps, crop covers, and emergency blankets.

Economic an Accessible

PCB manufacturing requires expensive, specialized machinery and the use of hazardous, controlled chemicals. In contrast, circuit embroidery is often created with low-cost materials and is significantly more affordable than traditional PCBs. The tools and machinery needed for embroidered circuits are widely available and easy to obtain, making this approach more accessible.

Short Cycle Time

Many e-textile processes benefit from very short design cycles. This is because of how accessible and economic the manufacturing processes are.

E-Textile Technologies

There are many types of e-textile technologies, such as woven, laminated, and embroidered. I will focus on technical embroidery as it is the current specialty of Digital Fiber.

What is Technical Embroidery

Technical Embroidery involves stitching electronic circuits into textiles using an embroidery machine and conductive thread. Tiny PCBs are often attached for control and sensing, enabling smart textiles and wearable technologies. Careful manufacturing practices ensure tight tolerances are maintained between the needle and PCB to prevent machine crashes.