Engineering Graphene Flakes for Wearable Textile Sensors via Highly Scalable and Ultrafast Yarn Dyeing Technique

[Image: see text] Multifunctional wearable e-textiles have been a focus of much attention due to their great potential for healthcare, sportswear, fitness, space, and military applications. Among them, electroconductive textile yarn shows great promise for use as next-generation flexible sensors without compromising the properties and comfort of usual textiles. However, the current manufacturing process of metal-based electroconductive textile yarn is expensive, unscalable, and environmentally unfriendly. Here we report a highly scalable and ultrafast production of graphene-based flexible, washable, and bendable wearable textile sensors. We engineer graphene flakes and their dispersions in order to select the best formulation for wearable textile application. We then use a high-speed yarn dyeing technique to dye (coat) textile yarn with graphene-based inks. Such graphene-based yarns are then integrated into a knitted structure as a flexible sensor and could send data wirelessly to a device via a self-powered RFID or a low-powered Bluetooth. The graphene textile sensor thus produced shows excellent temperature sensitivity, very good washability, and extremely high flexibility. Such a process could potentially be scaled up in a high-speed industrial setup to produce tonnes (∼1000 kg/h) of electroconductive textile yarns for next-generation wearable electronics applications.