Wearable e-textiles are able to perform electronic functions and are perceived as a way to add features into common wearable textiles, building competitive market advantages. The e-textile production has become not only a research effort but also an industrial production challenge. It is important to know how to use existing industrial processes or to develop new ones that are able to scale up production, ensuring the behavior and performance of prototypes. Despite the technical challenges, there are already some examples of wearable e-textiles where sensors, actuators, and production techniques were used to seamlessly embed electronic features into traditional wearable textiles, which allow for daily use without a bionic stigma.

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Work-related musculoskeletal disorders (WRMSDs) are a serious worldwide health concern, that can result in the worker's permanent disability and an economic burden of up to 2% of the Gross Domestic Product (GDP). This paper presents the design and development of an innovative smart garment for real-time ergonomic risk assessment. It aims to empower operators with posture awareness and provide objective data to ergonomists. The system is based on inertial sensors and implements a biofeedback strategy that uses haptic stimulus to warn the user about hazard postures, enabling more ergonomic postures. To allow an easy data analysis, a graphical interface was developed in MATLAB. This framework was validated with 5 subjects, in a simulated scenario with 5 tasks that included a collaborative robot arm. The results showed that providing real-time biofeedback to the subject improves posture awareness, and has a significant impact on reducing the ergonomic risk, with reductions of up to 39.8% of the time spent in hazard postures. The wearable technology and developed methodologies are a promising tool to complement the ergonomist diagnoses of hazard tasks and workspaces and to reduce the risk of musculoskeletal disorders. INDEX TERMS Ergonomic risk assessment, biofeedback, inertial measurement units, wearables design, WRMSDs.

Purpose The performance of parts produced by fused filament fabrication is directly related to the printing conditions and to the rheological phenomena inherent to the process, specifically the bonding between adjacent extruded paths/raster. This paper aims to study the influence of a set of printing conditions and parameters, namely, envelope temperature, extrusion temperature, forced cooling and extrusion rate, on the parts performance. Design/methodology/approach The influence of these parameters is evaluated by printing a set of test specimens that are morphologically characterized and mechanically tested. At the morphological level, the external dimensions and the voids content of the printed specimens are evaluated. The bonding quality between adjacent extruded paths is assessed through the mechanical performance of test specimens, subjected to tensile loads. These specimens are printed with all raster oriented at 90º relative to the tensile axis. Findings The best performance, resulting from a compromise between surface quality, dimensional accuracy and mechanical performance, is achieved with a heated printing environment and with no use of forced cooling. In addition, for all the conditions tested, the highest dimensional accuracy is achieved in dimensions defined in the printing plane. Originality/value This work provides a relevant result as the majority of the current printers comes without enclosure or misses the heating and envelope temperature control systems, which proved to be one of the most influential process parameter.

Purpose An issue when printing multi-material objects is understanding how different materials will perform together, especially because interfaces between them are always created. This paper aims to address this interface from a mechanical perspective and evaluates how it should be designed for a better mechanical performance. Design/methodology/approach Different interface mechanisms were considered, namely, microscopic interfaces that are based on chemical bonding and were represented with a U-shape interface; a macroscopic interface characterized by a mechanical interlocking mechanism, represented by a T-shape interface; and a mesoscopic interface that sits between other interface systems and that was represented by a dovetail shape geometry. All these different interfaces were tested in two different material sets, namely, poly (lactic acid)–poly (lactic acid) and poly (lactic acid)–thermoplastic polyurethane material pairs. These two sets represent high- and low-compatibility materials sets, respectively. Findings The results showed, despite the materials’ compatibility level, multi-material objects will have a better mechanical performance through a macroscopic interface, as it is based on a mechanical interlocking system, of which performance cannot be achieved by a simple face-to-face interface even when considering the same material. Originality/value The paper investigates the importance of interface design in multi-material 3D prints by fused filament fabrication. Especially, for parts intended to be subjected to mechanical efforts, simple face-to-face interfaces are not sufficient and more robust and macroscopic-based interface geometries (based on mechanical interlocking systems) are advised. Moreover, such interfaces do not raise esthetic problems because of their working principle; the 3D printing technology can hide the interface geometries, if required.