In this study, we explore how the strategic positioning of conductive yarns influences the performance of plated knit strain sensors fabricated using commercial knitting machines with both conductive and non-conductive yarns. Our study reveals that sensors with conductive yarns located at the rear, referred to as ‘purl plated sensors’, exhibit superior performance in comparison to those with conductive yarns at the front, or ‘knit plated sensors’. Specifically, purl plated sensors demonstrate a higher sensitivity, evidenced by a gauge factor ranging from 3 to 18, and a minimized strain delay, indicated by a 1% strain in their electromechanical response. To elucidate the mechanisms behind these observations, we developed an equivalent circuit model. This model examines the role of contact resistance within varying yarn configurations on the sensors’ sensitivity, highlighting the critical influence of contact resistance in conductive yarns subjected to wale-wise stretching on sensor responsiveness. Furthermore, our findings illustrate that the purl plated sensors benefit from the vertical movement of non-conductive yarns, which promotes enhanced contact between adjacent conductive yarns, thereby improving both the stability and sensitivity of the sensors. The practicality of these sensors is confirmed through bending cycle tests with an in situ monitoring system, showcasing the purl plated sensors’ exceptional reproducibility, with a standard deviation of 0.015 across 1000 cycles, and their superior sensitivity, making them ideal for wearable devices designed for real-time joint movement monitoring. This research highlights the critical importance of conductive yarn placement in sensor efficacy, providing valuable guidance for crafting advanced textile-based strain sensors.

With growing interest in wearable technologies, the development of flexible sensors and products that can monitor the human body while being comfortable to wear is gaining momentum. While various textile-based strain sensors have been proposed, their implementation in practical, exercise-specific applications remains limited. In this study, we developed a knitted strain sensor that monitors elbow angles, focusing on dumbbell exercise, which is a basic exercise in sports, and verified its performance. The material of the developed knitted strain sensor with a plain stitch structure comprised a silver-coated nylon conductive yarn and an acrylic/wool blended yarn. To evaluate the electrical and physical characteristics of the developed sensor, a textile folding tester was used to conduct 100 repeated bending experiments at three angles of 30°, 60°, 90° and speeds of 10, 30, 60 cpm. The system demonstrated excellent elasticity, high sensitivity (gauge factor = 698), fast responsiveness, and reliable performance under repeated stress, indicating its potential for integration into wearable fitness or rehabilitation platforms.

With growing interest in wearable technologies, the development of flexible sensors and products that can monitor the human body while being comfortable to wear is gaining momentum. However, can be directly integrated into textiles or clothing are lacking. In this study, we fabricated a knitted strain sensor that monitors elbow angles, focusing on dumbbell exercise, which is a basic exercise in sports, and verified its performance. The material of the fabricated knitted strain sensor with a plain stitch structure comprised a silver-plated conductive yarn and an acrylic/wool blended yarn. To evaluate the electrical and physical characteristics of the fabricated sensor, a textile folding tester was used to conduct 100 repeated bending experiments at three angles of 30°, 60°, and 90° and speeds of 10, 30, and 60 cpm. According to the results, the fabricated knitted strain sensor exhibits excellent elasticity, high sensitivity (gauge factor = 698), fast response, and excellent reproducibility and stability even under long-term repeated bending. Sensors with such excellent performance are expected to be used not only in real-time body monitoring but also in various wearable applications.