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With favorable properties of stretchability, stitchability, and potential to be woven into a fabric, thread-based sensors have gained considerable interest for wearable devices for smart and connected health applications. To facilitate wearable applications, an easy and reliable way to fabricate these thread-based sensors with good performance and consistency is the key while manufacturing these smart threads. In this paper, we propose an automated thread-coating system that can fabricate thread-based strain sensors with controlled parameters. The platform uses integrated sensors for controlled manufacturing of the threads in a highly compact structure that consists of an innovative tension sensor and a closed-loop thermal management system. Using this new system, a sample thread with a gauge factor of 1.47 and tension sensitivity of 32.64 KΩ/N is prepared. Compared with hand-coated thread, the machine-fabricated thread shows much better sensitivity and consistency. The prepared strain sensor is made into a respiration sensor patch and a limb motion patch to demonstrate its application.

Devices that can morph their functions on demand provide a rich yet unexplored paradigm for the next generation of electronic devices and sensors. For example, an antenna that can morph its shape can be used to adapt communication to different wireless standards or improve wireless signal reception. We utilize temperature-sensitive shape memory alloys (SMA) to realize a shape morphing antenna (ShMoA). In the designed architecture, multiple conjoined shape memory alloy sections form the antenna. The shape morphing of this antenna is achieved through temperature control. Different temperature threshold levels are used for programming the shape. Besides its conventional use for RF applications, ShMoA can serve as a multi-level temperature sensor, analogous to thermoreceptors in an insect antenna. ShMoA essentially combines the function of temperature sensing, embedded computing for detection of threshold crossings, and radio frequency readout, all in the single construct of a shape-morphing antenna (ShMoA) without the need for any battery or peripheral electronics. The ShMoA can be employed as bio-inspired wireless temperature sensing antennae on mobile robotic flies, insects, drones and other robots. It can also be deployed as programmable antennas for multi-standard wireless communication.