Optimization of PCB printing ink and textile substrates for enhanced e-textile performance and reliability

Smart and electronic textiles are rapidly advancing with technological progress. Numerous studies have explored the synthesis and application of carbon and graphene-based inks on various substrates. However, there remains a critical need to examine the parameters affecting the fabrication of carbon-based printed designs for e-textiles. This study investigates the effects of weave structure, ink type, and flow rate on the electric resistance and surface characteristics of textile fabrics used as substrates. Two fabric types, plain weave and twill weave, were used with three various types of inks including carbon, graphene-based, and textile reference inks. The best six samples from each weave type were washed and re-evaluated for electric resistance and surface properties, with plain weaves showing superior results. ANOVA statistical analysis revealed that ink type significantly impacts the electrical resistance of printed circuits. A printed patch from a reference ink sample was stitched onto a casual knitted t-shirt, demonstrating the potential for smart textile applications in embodied sensors, piezoelectric materials, and energy harvesting. These printed patches may be used in various smart and e-textile applications for various fields ranging from health, sports, leisure, etc.