Textile sensors: Sensor technology and antenna structures on textile substrates for industry and OEMs

Textile sensors consist of conductive materials (threads, wires, strands) that are integrated into a carrier textile using technical embroidery or other textile processes. Depending on the sensor type, they detect physical quantities such as pressure, temperature, humidity, or strain by measuring changes in the electrical resistance, capacitance, or inductance of the conductive structure when the measured quantity is applied. Unlike film or circuit board sensors, the textile carrier material remains flexible, stretchable, and in many cases, washable.

For textile applications, resistive and capacitive pressure sensors are particularly suitable, with their measuring structure embroidered directly onto a carrier textile. These sensors detect pressure distributions across the entire sensor surface rather than just at individual measuring points and adapt to curved or deformable surfaces. Typical applications include ergonomic optimization in seating and lying systems, safety mats, and medical applications such as pressure ulcer prevention.

Wash resistance depends on the combination of conductor material and carrier textile. Embroidered sensor structures are a mechanically integral part of the textile and therefore significantly more robust than printed or glued conductor tracks, which can delaminate when bent or washed. Embro designs the material combination for each project and validates the wash resistance in the sample process together with the customer.

Conventional sensors are mounted on rigid or semi-rigid substrates (circuit boards, polyimide films). Textile sensors are integrated directly into a flexible carrier textile, allowing them to be bent, stretched, and sewn or laminated into existing textile products. This is advantageous wherever flexibility in shape, low weight, comfort in contact with skin, or washability are required. For purely laboratory measurement applications without mechanical stress, conventional sensors remain the more accurate choice.

Material selection depends on the application requirements. Polyester is suitable as a cost-effective standard material for many industrial applications. Aramid fabrics are used in applications with high temperature loads. Medical nonwovens offer biocompatibility and skin contact compatibility for therapeutic and diagnostic products. Embro processes conductive materials including stainless steel wires, silver-coated threads, carbon fibers, and coated copper strands in ultra-fine diameters.

A typical project begins with a joint requirements analysis: measurement parameter, geometry, substrate material, environmental conditions, and planned quantity. This is followed by CAD-based sensor layout design, and then the production of initial functional prototypes for validation in the customer's product. After the optimization phase (material, layout, connection technology), series production begins. The entire process takes place in Falkenstein/Vogtland.

Textile NFC antennas on heat-resistant substrates function within a temperature range of 150 to 250 °C. Conventional foil tags fail in this range because the substrate deforms or the adhesive layer fails. Embroidered antenna structures on aramid or fiberglass fabrics retain their shape and function even under continuous heat exposure. UHF RFID antennas on textile substrates are also wash-resistant and suitable for industrial laundry applications.

Embro does not manufacture standalone textile temperature sensors as a separate product. What Embro offers in the field of temperature measurement is the integration of embroidered PTC thermistors into textile heating elements. These act as overtemperature protection, preventing a defined maximum temperature from being exceeded. Additionally, purchased temperature sensors can be integrated into textile products if you require temperature measurement within your product. For projects that require pure textile temperature measurement as a core function, we recommend a consultation to clarify technical feasibility and the most suitable approach.