5. E-textiles

Research & Exploration: Interactive Wearables

Overview

This week’s assignment focused on exploring the world of e-textiles—the fusion of electronic components with fabric to create interactive, functional garments. My project centered on enhancing the wearability and usability of a previously designed costume by incorporating a touch-sensitive interface into the electronics system.

Specifically, I set out to replace the physical button on the back of the costume—which previously activated the wing lighting—with a touch sensor. By moving the control to a more accessible location, such as the wrist, I aimed to create a smoother and more intuitive user experience. This change would allow the performer or wearer to activate the lighting without the awkwardness of reaching behind their back.

References & Inspiration

This project builds upon earlier work from Fab Academy 2024, particularly the custom PCB I designed for the backplate and wing system. The board was originally built to manage lighting effects across the wings, controlled by a simple mechanical button.

To make the system more user-friendly, I modified the existing PCB layout and hardware configuration to accommodate a capacitive touch sensor. This shift marks a meaningful step toward more seamless and gesture-based control systems for wearable technology.

Tools & Materials Used

• Arduino Uno
• Arduino IDE (Software)
• Custom PCB board (Fab Academy 2024)
• Copper tape (for the touch sensor)
• Conductive thread (optional for future wearable integration)

Process & Workflow

Step 1: Testing the Chip & Identifying Connection Points

The first task was to examine the existing PCB to locate the pins associated with the physical button. After identifying the correct connection point, I removed the button and prepared to replace it with a custom touch sensor.

To create the sensor, I used copper tape, arranging it in a pattern designed to maximize surface area while remaining discreet. This tape was adhered to the wrist area of the costume, ensuring it could be touched naturally during wear.

I ran initial tests to ensure the copper sensor responded correctly to human touch and could send signals to the microcontroller, mimicking the behavior of the original button.

Step 2: Coding the Touch Sensor

I developed a custom code in Arduino IDE to program the microcontroller to respond to touch input from the copper sensor. The code controlled the LEDs on the wings, turning them on or off based on a single tap.

The challenge here was to ensure the sensor was responsive and stable, preventing flickering or accidental triggers. Debounce timing and sensitivity thresholds were adjusted for reliability and smooth operation.

Code Example

// the setup function runs once when you press reset or power the board
void setup() {
  // initialize digital pin LED_BUILTIN as an output.
  pinMode(LED_BUILTIN, OUTPUT);
}

// the loop function runs over and over again forever
void loop() {
  digitalWrite(LED_BUILTIN, HIGH);   // turn the LED on (HIGH is the voltage level)
  delay(1000);                       // wait for a second
  digitalWrite(LED_BUILTIN, LOW);    // turn the LED off by making the voltage LOW
  delay(1000);                       // wait for a second
}

Step 3: Final Assembly & Testing

After the hardware and code were integrated, I carefully assembled the system into the costume. The sensor was secured at the wrist, wired to the PCB via jumper cables. Unfortunately, during the final round of testing, the chip overheated and burned out, likely due to a power supply misconfiguration or short circuit in one of the connections.

This prevented a live demonstration of the completed setup, but all preliminary tests with the sensor were successful.

I plan to revisit the setup with improved power protection and possibly switch to a more robust microcontroller to support future upgrades.

---

Reflection

This project provided valuable hands-on experience in merging electronics with textiles in a functional and user-centered way. Despite the hardware failure at the end, I was able to test and verify the core concept of replacing mechanical controls with touch-sensitive interfaces in wearable designs.

Key takeaways include: - The importance of testing hardware under realistic conditions - The need for proper voltage regulation and current protection - How user accessibility can be dramatically improved with thoughtful design choices

Moving forward, I intend to iterate on this prototype with more refined PCB designs, better power management, and potentially integrate conductive fabric to make the sensor completely embedded into the costume for an even cleaner look.

This exercise reinforced the creative possibilities of e-textiles and how they can be used to make wearables not only more functional, but also more magical and intuitive.

---

Next Steps

• Redesign the PCB with built-in touch sensor input ports
• Add voltage regulation circuits to prevent chip damage
• Explore conductive fabric or thread as alternatives to copper tape
• Produce a video demonstration once the revised prototype is working
• Document the updated version as a step-by-step guide for others