What is Digital Fiber?
- Rodney Trusty
- May 22
- 3 min read
by Rodney Trusty - admin@digitalfiber.us
Modern embedded systems rely on a proven process:
CAD tools for precise layout
Design rules that enforce reliability
Standardized manufacturing for repeatability and scale
This framework has enabled decades of rapid development in rigid PCB electronics.
As embedded systems increasingly demand flexible and wearable electronics, the same structured approach has not existed.
The Digital Fiber Ecosystem fills this gap. It provides a parallel ecosystem for electronic textiles that mirrors the rigor and efficiency of traditional embedded workflows:
CAD Tools → Digital Fiber Studio – Circuit layout specifically for embroidery
Design Rules → DF Standard: Electronic Embroidery Design – Validated electrical and mechanical guidelines for textile circuits
Manufacturing → DF Standard: Electronic Embroidery Manufacturing – Scalable workflows compatible with industrial embroidery equipment
Digital Fiber Studio is the central design tool in the Digital Fiber platform. It serves as a specialized electronic design automation (EDA) system for e-textiles, combining the capabilities of traditional circuit CAD tools like Altium with the precision of embroidery CAD software such as Wilcom Embroidery Studio. This hybrid approach significantly reduces development time and improves the reliability of textile-based electronic systems.
Key features include:
• Enforced design rules for both electronics and embroidery
• Path validation to prevent machine faults during production
• A curated library of sewable electronic components
• Automated trace routing for consistent and efficient layouts
Digital Fiber Studio supports a streamlined workflow for designing functional textiles, making it well-suited for applications where flexibility, durability, and integration are key.
What It Enables
To understand the impact of Digital Fiber, it helps to compare it to the traditional way soft circuits are made. Most wearable electronics today are built by hand, using conductive thread and manual layout. They work, but they often fall short in reliability and repeatability.
The Yendor Flex Glove, designed entirely in Digital Fiber Studio, shows what’s possible when e-textiles follow the same disciplined process as modern PCB design.
Traditional E-Textiles
• Hand-stitched conductive thread
• Fragile soldered connections
• Difficult to reproduce at scale
• Exposed components and uneven finish
Digital Fiber E-Textiles
• CAD-based embroidery layout
• Durable, machine-embroidered traces
• Easily replicated using industrial equipment
• Clean, fully integrated design
The video below shows the Yendor Flex Glove capturing finger flex and motion data in real time. Sensor values are streamed to a custom GUI for live monitoring. These same techniques could be adapted to track joint movement, detect falls, or monitor posture. Anywhere motion or flex sensing adds value.
Who is it for?
Digital Fiber is built for teams developing at the front edge of wearable tech with speed as a priority. It’s especially suited for:
Defense contractors developing next-generation wearable systems
R&D teams exploring textile-integrated sensors and circuits
Schools and Universities teaching E-Textiles
Embroidery Shops wanting to manufacture E-Textiles
Hobbyists and Makers looking to have fun
Educational Materials
Digital Fiber includes a set of foundational documents and guides to support both design and manufacturing:
Design Standards
DF Standard: Electronic Embroidery Design
Validated electrical and mechanical guidelines for creating reliable textile circuits.
Manufacturing Standards
DF Standard: Electronic Embroidery Manufacturing
Scalable methods for producing embroidered circuits using industrial equipment.
Technical References
The Anatomy of an Embroidered Circuit
A breakdown of circuit structure, material layers, and functional considerations.
DF Hardware Component List
A curated library of sewable components compatible with Digital Fiber Studio.
Digital Fiber Studio Manual
A complete user guide to the CAD environment, tools, and workflow.
To learn more about E-Textiles and Digital Fiber check out this blog Introduction to E-Textiles. There you'll find examples of wirelessly connected fabric, pressure sensitive fabric arrays and things of the sort. Go to Digital Fiber Studio for an overview of some of it's features.
Demonstrations
Biometric Vest
Biometric vest with pressure sensing array and water sensors. Additionally, There is I2C connection on the right sleeve and PWM on the left in case functional sleeves will be added in the future
Wirelessly Connected Textile Circuits
Joint Tracking
Pressure Sensitivity
Capacitive touch and LED arrays
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