Inkjet printing of functional inks on textiles to embed passive electronics devices and sensors is a novel approach in the space of wearable electronic textiles. However, achieving functionality such as conductivity by inkjet printing on textiles is challenged by the porosity and surface roughness of textiles. Nanoparticle-based conductive inks frequently cause blockage/clogging of inkjet printer nozzles, making it a less than ideal method for applying these functional materials. It is also very challenging to create a conformal conductive coating and achieve electrically conductive percolation with the inkjet printing of metal nanoparticle inks on rough and porous textile and paper substrates. Herein, a novel reliable and conformal inkjet printing process is demonstrated for printing particle-free reactive silver ink on uncoated polyester textile knit, woven, and nonwoven fabrics. The particle-free functional ink can conformally coat individual fibers to create a conductive network within the textile structure without changing the feel, texture, durability, and mechanical behavior of the textile. It was found that the conductivity and the resolution of the inkjet-printed tracks are directly related with the packing and the tightness of fabric structures and fiber sizes of the fabrics. It is noteworthy that the electrical conductivity of the inkjet-printed conductive coating on pristine polyethylene terephthalate fibers is improved by an order of magnitude by in situ heat-curing of the textile surface during printing as the in situ heat-curing process minimizes the wicking of the ink into the textile structures. A minimum sheet resistance of 0.2 ± 0.025 and 0.9 ± 0.02 Ω/□ on polyester woven and polyester knit fabrics is achieved, respectively. These findings aim to advance E-textile product design through integration of inkjet printing as a low-cost, scalable, and automated manufacturing process.

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Textile antennas are an integral part of the next generation personalized wearable electronics system. However, the durability of textile antennas are rarely discussed in the literature. Typical textile antennas are prone to damage during normal wearable user scenarios, washing, and heat cycling over time. Fabricating a durable, washable, flexible, and breathable (like textile materials) antenna is challenging due to the incompatibility of the mechanical properties of conductive materials and soft textile materials. This paper describes a scalable screen printing process on an engineered nonwoven substrate to fabricate microstrip patch antennas with enhanced durability. This work used an Evolon® nonwoven substrate with low surface roughness (∼Ra = 18 μm) and high surface area (∼2.05 mm2 mm−2 of fabric area) compared to traditional textile materials, which allows the ink to penetrate evenly in the fiber bulk with its strong capillary wicking force and enhances print resolution. The composite layer of ink and fiber is conductive and enables the antennas to maintain high mechanical flexibility without varying its RF (Radio Frequency) properties. Additionally, the antennas are packaged by laminating porous polyurethane web to make the device durable and washable. The fully packaged antennas maintain the structural flexibility and RF functionality after 15 cycles of washing and drying. To improve the air permeability and enhance flexibility the antenna is also modified by incorporating holes in the both patch and ground layer of the antenna. The antennas were analyzed before and after submerging in water to observe the effect of wetting and drying with respect to frequency response. The porous antenna with holes recovered 3x times faster than the one without holes (solid) from fully wet state (saturated with water) to the dry state, demonstrating its potential use as a moisture sensor system.