Design and Fabrication of Embroidered Textile Strain Sensors: An Alternative to Stitch-Based Strain Sensors

Smart textile sensors have been gaining popularity as alternative methods for the continuous monitoring of human motion. Multiple methods of fabrication for these textile sensors have been proposed, but the simpler ones include stitching or embroidering the conductive thread onto an elastic fabric to create a strain sensor. Although multiple studies have demonstrated the efficacy of textile sensors using the stitching technique, there is almost little to no information regarding the fabrication of textile strain sensors using the embroidery method. In this paper, a design guide for the fabrication of an embroidered resistive textile strain sensor is presented. All of the required design steps are explained, as well as the different embroidery design parameters and their optimal values. Finally, three embroidered textile strain sensors were created using these design steps. These sensors are based on the principle of superposition and were fabricated using a stainless-steel conductive thread embroidered onto a polyester–rubber elastic knit structure. The three sensors demonstrated an average gauge factor of [Formula: see text] over a 26% working range, low hysteresis ([Formula: see text]), and good repeatability after being pre-stretched over a certain number of stretching cycles.