Here, we present a facile method for rapid fabrication of low-cost, stretchable electrical interconnections for wearable electronics. Using a commercial sewing machine, thin metallic wires are sewn onto the wearable materials in a double-stitch zigzag pattern, with the second stitch being a water-soluble polyvinyl alcohol (PVA) thread. The stretchable pattern is secured onto a clothing (e.g., a glove) with a stretchable elastomer coating followed by dissolution of the PVA thread in water. The interconnections maintain a constant electrical conductivity for strains up to 50 % and bending cycles over 15000. As a proof of concept implementation, we sewed interconnects and a soft capacitive force sensor onto a latex glove to create a wearable tactile sensor with a linear sensitivity of 96 fF/N.
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The next generation electronics demand more human-friendly devices that have the ability to be easily integrated into clothing and garments for applications such as wearable health monitoring systems, human motion detection, and robotics. To address these demands, during the last decade numerous research groups have developed various different fabrication technologies that can be classified into three main categories. The first and early implementation relied on the fabrication of stretchable serpentine or herringbone configuration metal and semiconductor traces created via traditional micro-fabrication technologies . In this process the stretchable traces are either directly patterned or transfer printed onto an elastic substrate . The devices fabricated by this approach have resulted in highly integrated electronics with multifunctional capabilities. Various wearable and implantable devices have been reported using this approach, including stretchable and conformal sensors, batteries, and actuators .
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