TEXTILES.ORG
We are in the middle of a historic leap in textile technology. Whether it’s the development of new yarns and coatings or the integration of electronics into existing textiles, the future of wearable technology is rapidly evolving—and the future is bright. It seems like every week brings another breakthrough from research and development firms and universities, unveiling textiles that can sense, generate heat, cool and shape-shift in ways never seen before.
These advancements open exciting possibilities, but moving from innovation to large-scale, commercially viable products requires careful consideration. Developing functional, durable and manufacturable wearable technology comes with challenges—but also opportunities for creative problem-solving.
Bringing these technologies to market may be compared to running a 100-mile race through the desert. Is it possible? Yes. Is it inspiring? Yes. Is it logistically burdensome? Yes. Is it worth the effort? Absolutely—for both those driving innovation and those who benefit from it.
The durability and sourcing barrier
Washability is a critical factor in wearable technology. Laundering may be a limiting factor depending on how power-supplying or conductive textiles are created. Degradation must be considered, whether the conductive element is coated, applied post-production or integrated directly into the textile.
While many standard wash-cycle tests range from 10 to 20 cycles (depending on testing protocol requirements), power-supplying elements often begin to degrade well before 20 wash cycles. This isn’t always the case, but factors such as detergent type, water quality, wash-cycle settings and material type impact longevity.
Sourcing is another hurdle. Smart textiles and conductive materials are expensive and produced by a limited number of vendors worldwide. Long lead times, high costs and trade regulations add to the complexity of large-scale production. Even when these materials are available, they often require significant investment, making cost a key factor in determining commercial viability.
A complicated relationship
Powering textiles requires solving the challenge of seamlessly integrating soft and hard goods in a way that is both electrically and mechanically reliable while ensuring comfort and manufacturability. This makes for a somewhat complicated relationship between wearable tech and electronics.
This challenge can be approached in multiple ways, from permanently integrated electronics to modular electronics with interconnects, such as those used in Therabody Inc.’s RecoveryPulse series, designed to support patient recovery. Each approach comes with trade-offs in washability, charging, power delivery and overall user experience, and these must be carefully evaluated based on the specific application.
For integrated electronics, the electronics and enclosures must be designed to withstand environmental exposure and washing processes. The requirements for these systems can vary significantly. A tent or backpack will have vastly different durability and exposure concerns than an overgarment or undergarment.
A good starting point is to define the expected environment and cleaning methods. Then the necessary ingress protection ratings and temperature ranges for both the electronics and their enclosures can be determined. Fully encapsulated electronics offer strong protection, but they also create challenges for charging and external connections, as sealed components often require specialized solutions for power and data transfer.
Modular electronics, which can be removed for washing and charging, solve many design challenges that integrated electronics face, but they also introduce new ones. Exposed interconnects between modular electronics and textiles must be designed to withstand washing and drying without degrading electrical or material integrity. The interconnection area also adds size and weight, impacting comfort and wearability, particularly in garments designed for movement.
Both approaches must address the critical interface between the soft nature of textiles and the rigid nature of electronic components. This interface is where many failures occur. Flex cycles can degrade mechanical and electrical connections, textiles can wick moisture into the electronics and strain can pull apart conductive elements, all of which can compromise performance over time.
This soft-to-hard interface often is the most expensive part of the design, both in terms of engineering effort required to get it right and the manufacturing costs involved in creating reliable interconnections. If not properly designed, this area becomes a primary point of premature failure.
Bridging the soft-hard interface
Flexibility is both a challenge and a source of innovation. Stress is introduced into the system anytime a flexible or stretchable textile must connect to a rigid electronic component. This challenge is even greater in garments because stretch and movement compound strain on junction points. To reduce potential failure, engineers incorporate strain-relief designs, flexible epoxies and strategically positioned circuit boards and wiring, which can significantly lower warranty issues and premature degradation.
Material adherence is another major consideration. Many textiles feature coatings, dyes or functional films that provide important performance characteristics but can create adhesion barriers when integrating flexible circuit boards or heating elements. However, recent innovations are helping improve bonding techniques, making it possible to integrate electronics
more effectively.
Manufacturing complexity is an often-overlooked barrier. With global trade shifts and supply chain challenges, it can be difficult to find manufacturers that can handle both soft goods and electronics production. While a few vendors exist that offer full integration, they often require high minimum-order quantities or come at a significant cost.
Scaling wearable technology
Many wearable technological concepts perform well in controlled lab environments where sizes are limited and circumstances are controlled, but scaling them for real-world use requires additional refinement. Beyond demonstrating feasibility, product development must ensure that designs are durable, manufacturable and cost-effective at scale.
A significant amount of time and cost in development is spent defining expected operating environments, testing material durability and refining designs to handle real-world use. Even with rigorous testing, once a product reaches consumers, unexpected failure points often emerge.
For example, early versions of smart fitness apparel struggled with sensor degradation due to sweat exposure. Through multiple iterations, manufacturers improved waterproofing, material coatings and sensor integration, ultimately enhancing both performance and product longevity.
The reality is that no matter how much testing and refinement go into a product, once it reaches the market, it inevitably faces new scenarios. It’s a balance; designs can be developed to be foolproof, but the world will always find a way to challenge them.
Continuing to evolve
Despite the challenges, wearable technology continues to evolve, with new materials, smarter electronics integration and advanced manufacturing techniques shaping the next generation of products. Industries such as health care, sports performance and defense already see high demand for functional, durable wearables.
As industries continue to advance, collaboration among textile engineers, electronics specialists and manufacturers will be key to overcoming design challenges and unlocking new possibilities. The journey to commercialization is complex, but the progress made so far illustrates that it is possible. With continued investment in materials, engineering and manufacturing solutions, wearable technology will only become more sophisticated, durable and widely accessible.
Scaling wearable technology isn’t easy, but with the right approach, it’s an exciting challenge worth tackling.
Daniel McKewen is a senior soft goods developer, and Craig Morin is a senior electrical/biomedical engineer with Columbus, Ohio-based Priority Designs. Priority Designs is a product development and innovation firm that offers solutions in research, UX+UI, engineering, prototyping and soft goods.