Metal‐Textile Laser Welding for Wearable Sensors Applications

Electronic textile (E-textile), an emerging technology, has the potential to revolutionize consumer electronics by transforming them into wearable devices. Highly conductive, textile conductors, suitable for commercialization, have yet not been developed. Here, a new metal-textile laser welding method is presented for a rapid one-step, stable, and cost-efficient manufacturing of electrically conductive textiles. This method is a direct on-textile approach for customized 2D nanothick metal coatings with flexible design. Different metals, like palladium, silver, or copper can be welded on functional membranes and textiles containing polymers. As shown by bonding a copper 2D pattern on a polyamide textile, the resistivity does not vary if compared to the bulk material. The generated interlocking bonding ensures strong physical adhesion between the partly molten polyamide fibers and a copper layer, resisting up to 10 000 abrasion cycles using the standardized Martindale test and up to 42 000 flexion cycles using the industrial standardized Schildknecht test. A promising application for textile integrated conductors is body monitoring sensors. The feasibility of a laser welded resistance temperature sensors on a functional membrane is demonstrated without impairing its mechanical stability. This technology presents suitable properties and variabilities for a wide range of application in E-textiles and its commercialization.