The Commercialization of E-Textiles

Will e-textiles ever take off? Skeptics of this technology have questioned whether this technology will remain an underground innovation or become ubiquitous. They also wonder if commercialization is something attainable within the next few years, given there are some gaps and challenges standing in the way of progress. This is a legitimate concern, as there are some challenges standing in the way of commercialization: the potential environmental effects, design, standardization, cost, and a murky supply chain. When designing e-textile systems, these are the issues that may get in the way of a project moving forward. Let’s dive into each potential barrier.

E-Textiles and the Environment

With every move we make nowadays, the environment is top of mind. Creating e-textiles that have a reliable, energy-efficient power source and do not contribute to the mounting pile of electronic waste will be key to bringing these products to a market of consumers. This will be a tough bill to fill, but can be done with extensive research, and the cooperation of environmental organizations and partners who produce energy harvesting components. A few organizations and companies to partner with on this venture include, but are not limited to:

• The Consumer Products Safety Commision – The Consumer Products Safety Commission (CPSC) is committed to protecting consumers and families from products that pose a fire, electrical, chemical, or mechanical hazard. CPSC's work to ensure the safety of consumer products - such as toys, cribs, power tools, cigarette lighters, and household chemicals. They would ensure that any new technologies used would be safe for consumers.

• IPC - IPC is a global trade association dedicated to ensuring that electronics are built better, by furthering the competitive excellence and financial success of its members, who are participants in the electronics industry. IPC devotes resources to management improvement and technology enhancement programs, the creation of relevant standards, protection of the environment, and pertinent government relations. They are truly the best organization to partner with in this initiative.

• Smart Textile Alliance – The Smart Textile Alliance provides technical support for the advancement of industry standards and development of high-quality smart textile products. This organization aims to codify standards and mature the supply chain for smart textiles and are building these standards on structured stack that encompasses both electronics and textile components.

• NanoSD - NanoSD provides solutions to energy-related challenges through nanotechnology. They aim to help in the process of making products more dependent on energy harvesting technologies, such as solar power, and work directly with partner organizations like the US Department of Energy and the Department of Defense. They have also worked on adaptive textile projects, such as humidity responsive smart clothes and a smart reflective textile. So, they already have some solid experience in the smart textiles space.

Design

E-textiles can be designed a few ways, and with a variety of functions. E-textiles can also be textile based and non-textile based, so long as they are integrated into a textile down the line. Here are the most common forms on the market currently:

Conductive Ink and Components on Fabric 

Back in 2017, researchers at Harvard University explored a method of combining stretchable, conductive inks with electronic components to create wearable sensors that can then be applied to a material.  Conductive ink is probably the easiest and most accessible material for producing e-textiles, next to conductive thread.

Conductive Thread in Fabric   

Another method of making an e-textile system is by creating conductive patterns with conductive wire on a textile substrate. These conductive threads are typically made of metallic materials such as copper and silver, combined with filaments like polyester and polyamide. The only downside to standard conductive threads is their low mechanical resistance, which is why researchers at the University of West Bohemia have begun exploring hybrid conductive threads that possess a higher mechanical resistance.  

Electronics Embedded in Fabric 

Researchers from the Advanced Functional Fabrics of America (AFFOA) and MIT have discussed the possibility of embedding LEDs into fibers. When voltage is applied to the fibers, the LEDs detect light (or lack thereof) and light up. These fibers can be woven directly into a textile substrate.  

While the above methods are certainly effective and have been used for years, they are not going to take us into the next generation of e-textile products. We need to create systems that are free of wires and bulky components, and exist more as one entity, rather than a bunch of parts that need to be added separately. This will allow for easier integration into clothing, furnishings, and other consumer goods. However, to make the system recyclable, it should be made with disassembly in mind.

What Needs to Be Addressed

A big part of the commercialization of e-textiles and e-textile products is gaining the interest of investors. Like any innovation, money for research and development will not come unless there are proper regulations, the cost to produce is low, and there is a (virtually) flawless supply chain in place.

Standardization

The fact of the matter is, there is no one regulatory body dedicated to overseeing the production and implementation of e-textiles. This is something that organizations like the Smart Textile alliance are working towards. As of right now, there are a few private and government organizations that oversee certain aspects of production, but it is not their primary focus. Here are just a few.

AATCC – Test for washability and stretch of e-textiles. In March of 2019, the AATCC published EP013, a method of evaluating electrical resistance of electronically integrated textiles.  

ASTM – Focused on terminology, market, and characterization of e-textiles.  

IPC – E-textiles committee focused on guidelines for best practices in e-textile design and manufacturing.  

FTC – Oversees textile tagging regulations for e-textile products.  

Cost 

E-textiles are costly to produce. The only solutions that are on the low side cost wise are FR4 circuits, flex PCBs, and wired e-textiles; all of which are used in consumer electronics and wearables. It is important to keep in mind that the higher the cost to produce, the higher the price consumers will pay for an e-textile product. For the cost to be reduced, the price of electronic components will need to be lowered significantly.  

Supply Chain 

Among the largest hurdles when commercializing anything is establishing a streamlined supply chain. This has been a struggle for many disruptive technologies in the past, including Bluetooth. From materials sourcing to gaining the interest of consumer goods companies, the current supply chain for e-textiles is a bit inconsistent and there is no model to look to for guidance. Manufacturing is a huge part of the supply chain. You need a manufacturing partner to produce e-textiles, and depending on the company, the fees do not come cheap. The companies developing products made from e-textiles also need a facility that can work with the technology. There are several more technical obstacles, but these are the main ones.  

Rushi Patel of All About Circuits authored an article recently that explored the question of e-textiles being a pipe dream or future reality. There is this common feeling amongst some in engineering and design that e-textiles and the widespread use of them is something so far out of reach, we will never achieve it (or it will take us many years to do so). The truth is, we will achieve this because we are already halfway there. So long as we address the issues mentioned above and stay steadfast in our pursuit of products that not only work for consumers, but work with consumers, there is absolutely no reason we cannot reach this goal by 2025. Let’s get to work!