Wearable devices such as smartwatches and fitness trackers have become part of everyday life, helping people monitor their heart rate, activity, and sleep.
But scientists are already working on the next generation of wearable technology—electronics so thin, soft, and flexible that they could be sewn into clothing or even used like medical stitches.
Researchers at Tufts University have developed a new type of thread-based electronic circuit that bends, stretches, twists, and moves naturally with the body.
The study, published in ACS Applied Materials & Interfaces, describes a technology that could one day make health monitoring far more comfortable and less noticeable than today’s wearable devices.
Instead of building electronic circuits on flat, rigid materials, the research team created every major component of an integrated circuit—including transistors and sensors—in the form of flexible threads.
These electronic threads can be stitched into fabric, wrapped around curved surfaces, or placed directly on the skin without restricting movement.
The researchers believe this approach could lead to wearable devices that feel more like ordinary clothing than electronic hardware.
Future versions could continuously track a wide range of health signals and environmental conditions. Artificial intelligence could then analyze the collected data to provide useful information about a person’s fitness, health, recovery from illness or injury, and overall well-being.
The technology may also have important medical applications. Researchers envision thread-like electronics being used as surgical sutures that monitor how wounds are healing inside the body. Other possible uses include tracking changes in movement that may signal cognitive decline, monitoring fall risk in older adults, or measuring breathing patterns in babies.
To demonstrate the technology, the team built several working prototypes. One lightweight device was placed on the temple to detect blinking, while another was positioned near the diaphragm to monitor breathing rate and breathing patterns. These early demonstrations show that the electronic threads can successfully detect subtle body movements while remaining soft and flexible.
A key part of the new technology is a special material called a eutectogel. This soft gel connects different parts of the electronic thread while remaining flexible and stable. Earlier designs often relied on hydrogels, which can dry out over time. The new gel is more durable and is suitable for use on or even inside the human body.
The eutectogel offers another useful advantage—it can repair itself. If the gel is damaged, bringing the broken pieces back together and applying gentle heat can restore both its physical structure and its electrical performance. Although the thread itself cannot repair a complete cut, the gel connections can recover after damage.
The manufacturing process is also much simpler than traditional electronics. Conventional computer chips require expensive clean rooms and complex high-temperature manufacturing techniques. In contrast, these thread-based circuits can be produced using lower-cost methods that are better suited for soft materials and textiles.
The researchers emphasize that the technology is still in its early stages. They plan to improve both the manufacturing process and the complexity of the electronic circuits in future versions.
If successful, these nearly invisible electronic threads could eventually become part of everyday clothing, medical devices, or even surgical materials, allowing people to monitor their health continuously without feeling like they are wearing electronics at all.
