Recent advances in fiber-based actuators have spotlighted twisted, coiled polymer actuators (TCPAs) as a promising technology, offering a combination of high energy density, cost-effectiveness, and environmental sustainability. A comprehensive review of current literature underscores the potential of TCPAs while also revealing significant drawbacks in scaling production and maintaining stability for widespread textile integration. Our research directly addresses these challenges through an innovative manufacturing concept rooted in false-twisting techniques. The approach enables rapid, continuous production of intensely twisted polymer monofilaments, simultaneously allowing for the seamless incorporation of functional elements for thermal actuation and sensory capabilities. The study delves into the impact of this additional helical tier, alongside critical parameters, such as twist intensity, thermal processing conditions, and chirality, on the actuator’s contractile behavior. Exploiting the inherent structural integrity of plied yarns, we demonstrate the feasibility of processing these advanced TCPAs using conventional textile equipment. This may facilitate the creation of complex, multi-yarn contractile systems through circular braiding techniques, effectively producing artificial muscles at a scale previously unattainable. The findings reveal that monofilament coils can achieve remarkable contraction rates of up to 60%, with a direct correlation between twist density and actuator efficiency in single-filament configurations. Interestingly, this relationship becomes more nuanced in plied-yarn structures, where the interplay between polymer chain orientation and yarn-level twisting leads to enhanced contractile performance through synergistic effects. This work not only advances the theoretical understanding of TCPA behavior but also presents a practical pathway for their integration into large-scale textile applications. By bridging the gap between laboratory concepts and industrial feasibility, the next generation of smart textiles and wearable technologies could be powered by TCPAs.