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<p>Conformable and breathable textile structures are ideal for flexible wearable pressure sensors, yet challenges remain in scalable fabrication, easy integration, and programmability. This study presents a cost-effective and customizable method to create fully textile-based pressure sensors using machine embroidery, enabling seamless integration into smart wearable systems. Two sensing configurations were developed: a single-layer satin block embroidered with conductive yarn, which exhibited high piezoresistivity, fast response (35&#xa0;ms), quick recovery (16&#xa0;ms), and robust durability over 5000 press-and-release cycles, proven effective for monitoring activities such as plantar pressure and muscle contraction, and making it suitable for personalized health and fitness applications. The second configuration, a double-layer embroidery sensor with a conductive path and two parallel spacers anchored beneath a satin block, allows for array integration with minimal wiring, demonstrated by a 3 × 3 sensing array that, with the help of a convolutional neural network (CNN) machine learning model, accurately recognized handwritten numbers (0–9) with a 98.5% accuracy, showing its potential for user authentication and secure passcode entry. These findings underscore the potential of machine embroidery for developing scalable, integrated, and high-performance intelligent textile systems, paving the way for wearable technologies that are customizable, comfortable, and aesthetically appealing for a wide range of applications.</p> Graphical Abstract <p></p>

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Programmable and Scalable Embroidery Textile Resistive Pressure Sensors for Integrated Multifunctional Smart Wearable Systems

  • 期刊论文

  • 发表日期：

    2025年1月7日

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  • Yiduo Yang,
  • Yu Chen,
  • Yang Liu,
  • Rong Yin

摘要

Conformable and breathable textile structures are ideal for flexible wearable pressure sensors, yet challenges remain in scalable fabrication, easy integration, and programmability. This study presents a cost-effective and customizable method to create fully textile-based pressure sensors using machine embroidery, enabling seamless integration into smart wearable systems. Two sensing configurations were developed: a single-layer satin block embroidered with conductive yarn, which exhibited high piezoresistivity, fast response (35 ms), quick recovery (16 ms), and robust durability over 5000 press-and-release cycles, proven effective for monitoring activities such as plantar pressure and muscle contraction, and making it suitable for personalized health and fitness applications. The second configuration, a double-layer embroidery sensor with a conductive path and two parallel spacers anchored beneath a satin block, allows for array integration with minimal wiring, demonstrated by a 3 × 3 sensing array that, with the help of a convolutional neural network (CNN) machine learning model, accurately recognized handwritten numbers (0–9) with a 98.5% accuracy, showing its potential for user authentication and secure passcode entry. These findings underscore the potential of machine embroidery for developing scalable, integrated, and high-performance intelligent textile systems, paving the way for wearable technologies that are customizable, comfortable, and aesthetically appealing for a wide range of applications.

Graphical Abstract