Soft Wearables

Sensor-embedded garments detecting posture and movement with threadlike capacitive sensors

Challenge

Identifying compelling business case for a novel thread-like sensor
Developing and testing processes for embedding sensors into soft garments
Design and prototype wearables with novel thread-like sensors embedded

Outcome

Shifted focus from luxury goods to needs-based applications
Applied seamless no-sew construction to embed sensors and wiring in a skin safe base layer
Developed new soft connections for textile sensors

I brought softgoods prototyping expertise to MENRVA, a mechatronics research lab at Simon Fraser University, working with their engineers to productize a novel threadlike sensor.

Sensor Patches

The biggest challenge with the sensor was creating a consistent way of attaching the sensor to garments.

Could be replicated outside of the lab
Provides some layer the fragile sensor
Prevents overstretching
Good activation (stretch) in relation to surrounding material

Array of sensors embroidered to on a stretch panel

process documentation

Tracing

The lab was working to create use cases for a novel capacitive stretch sensor. The delicate and threadlike elastic needed to be integrated into soft textiles worn close to the body. I developed the following;

Stretchable for tracing the sensor circuit to a control board
Method for connection threadlike sensor to tracing
Skin-safe routing on a stretch garment
Bracing our delicate sensor to protect from overstretching

Evaluating performance of different patterns

Testing swatches of stretchable tracing

Shirt

After coming to understand the material properties of the sensor, constraints were established and the design took shape

conductive steel thread was used to preserve accurate capacitive sensing
tracing was routed through the extra layer of material and polyurethane adhesive strategically to direct maximum stretch onto the sensor
laser cut patches with sensors embedded were assembled, stitched to the tracing, and bonded in place on the exterior of the garment
waffle looking patches were designed to avoid direct heat on the sensor and not restrict stretch in that region the patch is applied

No pictures of earlier prototypes survived — they were bright pink waffle-looking things and they were awesome.

Tracing - Inside back

Tracing - Inside front

Tracing - All sew up with wires protruding to the board placement area

Tracing protrudes in the front where the board will be positioned

Tracings terminate securely using a stitch through a heat-set conductive patch.

A conductive thread zig-zag in bonded compression channels

Laser cut sensor patch with backing. Conductive fabric spots hold the sensor in place on the patch

Concept Illustrations

Outside of prototyping implementations, I was also tapped to illustrate research concepts for stakeholder presentations, IP applications, pitch competitions, grants and funding.

Vest concept all laced up with sensors

Early digital sketches of a sports shirt

Base layer with sensors to detect knee and him articulation

Smart scrubs to reduce workplace back injuries in nursing

Physio tape concept

Physio tape in situ

Illustrating a chair with embedded sensors in textile

Illustrating sensor-loaded home textiles

Something a bit different - a ski with sensors

IP & Research Support

In some cases I helped out engineers with diagrams and visuals for papers & IP applications

Risky postures

The shirt was designed to reduce workplace back injuries for nurses. This illustrations show the movements and postures we aimed to detect and mitigate.