Automated Fabrication of Smart Strain Sensing Threads

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.