Conductive tracks are key constituents of wearable electronics and e-textiles, as they form the interconnective links between wearable electrical devices/systems. They are made by coating or printing conductive patterns or tracks on textiles or by weaving, knitting, or embroidering conductive yarns into textiles. Screen printing is a mature and cost-effective fabrication method that is used in the textile industry. It allows a high degree of geometric freedom for the design of conductive patterns or tracks. Current screen-printed conductive textiles have the limitations of low durability when washed or when placed under bending, and they typically require encapsulation layers to protect the printed conductor. This paper presents a printable paste formulation and fabrication process based on screen printing for achieving a flexible and durable conductive polyester-cotton textile using an inexpensive carbon as the conductor. The process does not require an interface, the smoothing of the textile, or an encapsulation layer to protect the conductor on the textile. A resistivity of 4 × 10⁻² Ω·m was achieved. The textile remains conductive after 20 standard washes, resulting in the conductor’s resistance increasing by 140%. The conductive textile demonstrated less than ±10% resistance variation after bending for 2000 cycles.

An electrode is a fundamental element used in many electrotherapy devices. This work presents a novel dry electrode made from carbon and silicone rubber materials for wearable electrotherapy applications. The electrode was mixed using a speed mixer and fabricated using stencil printing. This paper investigates the resistivity change of the electrode under the pressure from 0 mmHg to 32.4 mmHg; and the skin–electrode impendence with the current frequency from 20 Hz to 10,000 Hz. The resistivity of the novel dry electrode is 24.6 ± 1.5 Ω∙m when the pressure on electrode is 17.7 mmHg. The skin–electrode impedance reduced from 1001.6 Ω to 145.3 Ω when the frequency increased from 20 Hz to 10,000 Hz.

Electrotherapy is a common therapeutic treatment used in pain relief. This paper presents the materials and fabrication methods used to manufacture an electrode textile for electrotherapy application. The Young’s modulus of the electrode is 0.22 MPa. The electrode textile consists of conductive tracks sandwiched between an interface layer and an encapsulation layer, and an electrode layer printed directly on top of the conductive grid patterns. The interface, conductive silver, and encapsulation layers were directly printed on fabric using screen printing. The electrode layer was printed using stencil printing. The electrode textile can survive 10,000 bending cycles around a cylinder with a diameter of 30 mm and 20 washes in a commercial washing machine.

This work presents the design and test of an e-textile based functional electrical stimulation system for post-stroke upper limb rehabilitation. The prototype was tested on five stroke survivors to assess stimulation comfort, the stimulation intensity required to achieve hand opening, and ease of use. Wrist extension was measured using two inertial measurement units. The wearable e-textile prototype achieved similar stimulation comfort compared to high-quality hydrogel electrodes with a score difference of between 0 and 1. The stimulation intensity to achieve full hand opening was the same for the hydrogel electrodes and the e-textiles for all five participants. A second design based on a knitted sleeve has been assessed in terms of usability. Additional new designs have been proposed to improve the usability.

This study examines the durability of stretchable conductive tracks on knitted fabrics. Two knitted fabrics with three designs of conductive tracks are tested to assess the fabric strain release and resistance change after a 50% elongation. The optimised design, made with all needle back jacquard knitting with sinusoidal conductive tracks, exhibits a 4% increase in fabric length and a 0.23 Ω (38.9%) increase in resistance. This e-textile is used to fabricate a sleeve with integrated functional electrical stimulation (FES) for stroke rehabilitation. The optimised electrode pattern, designed for stroke arm/hand rehabilitation, was achieved through co-design with stroke survivors and healthcare professionals. The prototype was tested on stroke survivors to assess stimulation comfort and ease of use. Tests have confirmed that the electrode sleeve (e-sleeve) is comfortable to wear and that stroke survivors are able to don and doff the e-sleeve using a single hand, facilitating independent home use.