Imagine wearing a T-shirt that monitors your heart rate or socks that track your running stride. This futuristic idea is now closer to reality, thanks to new research from Washington State University (WSU).
A team of researchers led by Hang Liu, an associate professor in the Department of Apparel, Merchandising, Design, and Textiles at WSU, has developed a method for 3D-printing smart fabrics that are not only durable but also comfortable to wear.
Their findings were recently published in the journal ACS Omega.
In the past, most attempts to create smart fabrics—clothing with technology built in—resulted in stiff, uncomfortable garments. Sensors or conductive threads were glued, woven, or sewn into the fabric, often making them rigid and less practical for everyday wear.
Liu’s team wanted to change that.
“If you are wearing a T-shirt with 3D-printed material for sensing purposes, you want it to fit snugly and be flexible and soft,” Liu explained. “If it’s stiff, it won’t be comfortable, and its sensing ability will suffer.”
To solve this problem, the researchers used a technique called direct ink writing 3D printing.
This method allowed them to print a special solution made of polybutylene succinate—a biodegradable polyester—mixed with carbon nanotubes directly onto two types of fabric.
Polybutylene succinate is strong, flexible, and blends well with natural fibers, while the carbon nanotubes add electrical conductivity, making the fabric capable of sensing movement and transmitting data.
What sets this technology apart is its durability. The team tested the printed fabrics for strength, conductivity, and their ability to work as motion sensors. After 20 cycles of washing and drying, the fabrics still performed well.
Even after 200 abrasion cycles and 500 cycles of stretching and relaxing, the material did not crack or lose its abilities. This durability is a big step forward for smart fabrics, which often break down after just a few washes.
Another important part of the research was its environmental impact. Instead of using toxic chemicals to process the materials, the team used Cyrene, a biodegradable and non-toxic solvent. This makes the production process safer for the environment, a rare consideration in the world of advanced fabric technology.
This study is part of the doctoral work of Zihui Zhao, one of Liu’s students. Liu herself has been working on smart fabrics for several years, previously developing a fiber that is as soft as cotton but can conduct electricity. Her recent work focuses on making smart fabrics that can sense and monitor information, a crucial step toward wearable technology.
While this is a major breakthrough, Liu notes that it is only part of the puzzle. To fully develop smart clothing, researchers still need to find ways to power the sensors and transmit the data they collect.
Even so, the research marks a significant leap toward everyday clothing that can monitor health, aid first responders, and enhance athletic performance.
