Thermally Drawn Highly Conductive Fibers with Controlled Elasticity

Fibres-threads of intelligence-enable a new generation of wearable systems

Fabrics represent a unique platform for seamlessly integrating electronics into everyday experiences. The advancements in functionalizing fabrics at both the single fibre level and within constructed fabrics have fundamentally altered their utility. The revolution in materials, structures, and functionality at the fibre level enables intimate and imperceptible integration, rapidly transforming fibres and fabrics into next-generation wearable devices and systems. In this review, we explore recent scientific and technological breakthroughs in smart fibre-enabled fabrics. We examine common challenges and bottlenecks in fibre materials, physics, chemistry, fabrication strategies, and applications that shape the future of wearable electronics. We propose a closed-loop smart fibre-enabled fabric ecosystem encompassing proactive sensing, interactive communication, data storage and processing, real-time feedback, and energy storage and harvesting, intended to tackle significant challenges in wearable technology. Finally, we envision computing fabrics as sophisticated wearable platforms with system-level attributes for data management, machine learning, artificial intelligence, and closed-loop intelligent networks.

Water-Based Continuous Fabrication of Highly Elastic Electromagnetic Fibers

Elastic electromagnetic fibers are promising building blocks for next-generation flexible electronics. However, fabrication of elastic fibers is still difficult and usually requires organic solvents or high temperatures, restricting their widespread applications. Furthermore, the continuous production of electromagnetic fibers has not been realized previously. In this study, we propose an ionic chelation strategy to continuously produce electromagnetic fibers with a magnetic liquid metal (MLM) as the core and elastic polyurethane as the sheath in water at room temperature. Sodium alginate (SA) has been introduced to rapidly chelate with calcium ions (Ca2+) in a coagulation bath to support the continuous spinning of waterborne polyurethane (WPU) as a sheath. Meanwhile, WPU-encapsulated MLM microparticles efficiently suppress the fluid instability of MLM for continuous extrusion as the core. The resultant fiber exhibits excellent mechanical performances (tensile strength and toughness up to 32 MPa and 124 MJ/m3, respectively), high conductive stability in large deformations (high conductivity of 7.6 × 104 S/m at 580% strain), and magnetoactive properties. The applications of this electromagnetic fiber have been demonstrated by conductance-stable wires, sensors, actuation, and electromagnetic interference shielding. This work offers a water-based molecular principle for efficient and green fabrication of multifunctional fibers and will inspire a series of applications.

Zebra-Patterned Stretchable Helical Yarn for Triboelectric Self-Powered Multifunctional Sensing

Smart textiles capable of both energy harvesting and multifunctional sensing are highly desirable for next-generation portable electronics. However, there are still challenges that need to be conquered, such as the innovation of an energy-harvesting model and the optimization of interface bonding between fibers and active materials. Herein, inspired by the spiral structure of natural vines, a highly stretchable triboelectric helical yarn (TEHY) was manufactured by twisting the carbon nanotube/polyurethane nanofiber (CNT/PU NF) Janus membrane. The TEHY had a zebra-stripe-like design that was composed of black interval conductive CNTs and white insulative PU NFs. Due to the different electron affinity, the zebra-patterned TEHY realized a self-frictional triboelectric effect because the numerous microscopic CNT/PU triboelectric interfaces generated an alternating current in the external conductive circuit without extra external friction layers. The helical geometry combined with the elastic PU matrix endowed TEHY with superelastic stretchability and outstanding output stability after 1000 cycles of the stretch-release test. By virtue of the robust mechanical and electrical stability, the TEHY can not only be used as a high-entropy mechanical energy harvester but also serve as a self-powered sensor to monitor the stretching or deforming stimuli and human physiological activities in real time. These merits manifested the versatile applications of TEHY in smart fabrics, wearable power supplies, and human-machine interactions.

Thermally Drawn-Based Microtubule Soft Continuum Robot for Cardiovascular Intervention

Cardiovascular disease is becoming the leading cause of human mortality. In order to address this, flexible continuum robots have emerged as a promising solution for miniaturizing and automating vascular interventional equipment for diagnosing and treating cardiovascular diseases. However, existing continuum robots used for vascular intervention face challenges such as large cross-sectional sizes, inadequate driving force, and lack of navigation control, preventing them from accessing cerebral blood vessels or capillaries for medical procedures. Additionally, the complex manufacturing process and high cost of soft continuum robots hinder their widespread clinical application. In this study, we propose a thermally drawn-based microtubule soft continuum robot that overcomes these limitations. The proposed robot has cross-sectional dimensions several orders of magnitude smaller than the smallest commercially available conduits, and it can be manufactured without any length restrictions. By utilizing a driving strategy based on liquid kinetic energy advancement and external magnetic field for steering, the robot can easily navigate within blood vessels and accurately reach the site of the lesion. This innovation holds the potential to achieve controlled navigation of the robot throughout the entire blood vessel, enabling in situ diagnosis and treatment of cardiovascular diseases.

Fiber-based Probes for Electrophysiology, Photometry, Optical and Electrical Stimulation, Drug Delivery, and Fast-Scan Cyclic Voltammetry In Vivo

Recording and modulation of neuronal activity enables the study of brain function in health and disease. While translational neuroscience relies on electrical recording and modulation techniques, mechanistic studies in rodent models leverage genetic precision of optical methods, such as optogenetics and imaging of fluorescent indicators. In addition to electrical signal transduction, neurons produce and receive diverse chemical signals which motivate tools to probe and modulate neurochemistry. Although the past decade has delivered a wealth of technologies for electrophysiology, optogenetics, chemical sensing, and optical recording, combining these modalities within a single platform remains challenging. This work leverages materials selection and convergence fiber drawing to permit neural recording, electrical stimulation, optogenetics, fiber photometry, drug and gene delivery, and voltammetric recording of neurotransmitters within individual fibers. Composed of polymers and non-magnetic carbon-based conductors, these fibers are compatible with magnetic resonance imaging, enabling concurrent stimulation and whole-brain monitoring. Their utility is demonstrated in studies of the mesolimbic reward pathway by simultaneously interfacing with the ventral tegmental area and nucleus accumbens in mice and characterizing the neurophysiological effects of a stimulant drug. This study highlights the potential of these fibers to probe electrical, optical, and chemical signaling across multiple brain regions in both mechanistic and translational studies.

Stretchable electronic strips for electronic textiles enabled by 3D helical structure

The development of stretchable electronic devices is a critical area of research for wearable electronics, particularly electronic textiles (e-textiles), where electronic devices embedded in clothing need to stretch and bend with the body. While stretchable electronics technologies exist, none have been widely adopted. This work presents a novel and potentially transformative approach to stretchable electronics using a ubiquitous structure: the helix. A strip of flexible circuitry ('e-strip') is twisted to form a helical ribbon, transforming it from flexible to stretchable. A stretchable core-in this case rubber cord-supports the structure, preventing damage from buckling. Existing helical electronics have only extended to stretchable interconnects between circuit modules, and individual components such as printed helical transistors. Fully stretchable circuits have, until now, only been produced in planar form: flat circuits, either using curved geometry to enable them to stretch, or using inherently stretchable elastomer substrates. Helical e-strips can bend along multiple axes, and repeatedly stretch between 30 and 50%, depending on core material and diameter. LED and temperature sensing helical e-strips are demonstrated, along with design rules for helical e-strip fabrication. Widely available materials and standard fabrication processes were prioritized to maximize scalability and accessibility.

Recent Research on Preparation and Application of Smart Joule Heating Fabrics

Multifunctional wearable heaters have attracted much attention for their effective applications in personal thermal management and medical therapy. Compared to passive heating, Joule heating offers significant advantages in terms of reusability, reliable temperature control, and versatile coupling. Joule-heated fabrics make wearable electronics smarter. This review critically discusses recent advances in Joule-heated smart fabrics, focusing on various fabrication strategies based on material-structure synergy. Specifically, various applicable conductive materials with Joule heating effect are first summarized. Subsequently, different preparation methods for Joule heating fabrics are compared, and then their various applications in smart clothing, healthcare, and visual indication are discussed. Finally, the challenges faced in developing these smart Joule heating fabrics and their possible solutions are discussed.

T-DOpE probes reveal sensitivity of hippocampal oscillations to cannabinoids in behaving mice

Understanding the neural basis of behavior requires monitoring and manipulating combinations of physiological elements and their interactions in behaving animals. We developed a thermal tapering process enabling fabrication of low-cost, flexible probes combining ultrafine features: dense electrodes, optical waveguides, and microfluidic channels. Furthermore, we developed a semi-automated backend connection allowing scalable assembly. We demonstrate T-DOpE (Tapered Drug delivery, Optical stimulation, and Electrophysiology) probes achieve in single neuron-scale devices (1) high-fidelity electrophysiological recording (2) focal drug delivery and (3) optical stimulation. The device tip can be miniaturized (as small as 50 µm) to minimize tissue damage while the ~20 times larger backend allows for industrial-scale connectorization. T-DOpE probes implanted in mouse hippocampus revealed canonical neuronal activity at the level of local field potentials (LFP) and neural spiking. Taking advantage of the triple-functionality of these probes, we monitored LFP while manipulating cannabinoid receptors (CB1R; microfluidic agonist delivery) and CA1 neuronal activity (optogenetics). Focal infusion of CB1R agonist downregulated theta and sharp wave-ripple oscillations (SPW-Rs). Furthermore, we found that CB1R activation reduces sharp wave-ripples by impairing the innate SPW-R-generating ability of the CA1 circuit.

Continuous Melt Spinning of Adaptable Covalently Cross-Linked Self-Healing Ionogel Fibers for Multi-Functional Ionotronics

Stretchable conductive fibers play key roles in electronic textiles, which have substantial improvements in terms of flexibility, breathability, and comfort. Compared to most existing electron-conductive fibers, ion-conductive fibers are usually soft, stretchable, and transparent, leading to increasing attention. However, the integration of desirable functions including high transparency, stretchability, conductivity, solvent resistance, self-healing ability, processability, and recyclability remains a challenge to be addressed. Herein, a new molecular strategy based on dynamic covalent cross-linking networks is developed to enable continuous melt spinning of the ionogel fiber with the aforementioned properties. As a proof of concept, adaptable covalently cross-linked ionogel fibers based on dimethylglyoximeurethane (DOU) groups (DOU-IG fiber) are prepared. The resultant DOU-IG fiber exhibited high transparency (>93%), tensile strength (0.76 MPa), stretchability (784%), and solvent resistance. Owing to the dynamic of DOU groups, the DOU-IG fiber shows high healing performance using near-infrared light. Taking advantage of DOU-IG fibers, multifunctional ionotronics with the integration of several desirable functionalities including sensor, triboelectric nanogenerator, and electroluminescent display are fabricated and used for motion monitoring, energy harvesting, and human-machine interaction. It is believed that these DOU-IG fibers are promising for fabricating the next generation of electronic textiles and other wearable electronics.

Towards High Efficiency and Rapid Production of Room-Temperature Liquid Metal Wires Compatible with Electronic Prototyping Connectors

We present in this work new methodologies to produce, refine, and interconnect room-temperature liquid-metal-core thermoplastic elastomer wires that have extreme extendibility (>500%), low production time and cost at scale, and may be integrated into commonly used electrical prototyping connectors like a Japan Solderless Terminal (JST) or Dupont connectors. Rather than focus on the development of a specific device, the aim of this work is to demonstrate strategies and processes necessary to achieve scalable production of liquid-metal-enabled electronics and address several key challenges that have been present in liquid metal systems, including leak-free operation, minimal gallium corrosion of other electrode materials, low liquid metal consumption, and high production rates. The ultimate goal is to create liquid-metal-enabled rapid prototyping technologies, similar to what can be achieved with Arduino projects, where modification and switching of components can be performed in seconds, which enables faster iterations of designs. Our process is focused primarily on fibre-based liquid metal wires contained within thermoplastic elastomers. These fibre form factors can easily be integrated with wearable sensors and actuators as they can be sewn or woven into fabrics, or cast within soft robotic components.

Programmable and Weldable Superelastic EGaIn/TPU Composite Fiber by Wet Spinning for Flexible Electronics

As an essential component of flexible electronics, superelastic conductive fibers with good mechanical and electrical properties have drawn significant attention, especially in their preparation. In this study, we prepared a superelastic conductive fiber composed of eutectic gallium-indium (EGaIn) and thermoplastic polyurethane (TPU) by simple wet spinning. The composite conductive fiber with a liquid metal (LM) content of 85 wt % achieved a maximum strain at a break of 659.2%, and after the conductive pathway in the porous structure of the composite fibers was fully activated, high conductivity (1.2 × 105 S/m) was achieved with 95 wt % LM by mechanical sintering and training processes. The prepared conductive fibers exhibited a stable resistive response as the fibers were strained and could be sewn into fabrics and used as wearable strain sensors to monitor various human motions. These conductive fibers can be molded into helical by heating, and they have excellent electrical properties at a maximum mechanical strain of 3400% (resistance change <0.27%) with a helical index of 11. Moreover, the conductive fibers can be welded to various two or three-dimensional conductors. In summary, with a scalable manufacturing process, weldability, superelasticity, and high electrical conductivity, EGaIn/TPU composite fibers fabricated by wet spinning have considerable potential for flexible electronics.

High-Hole-Mobility Fiber Organic Electrochemical Transistors for Next-Generation Adaptive Neuromorphic Bio-Hybrid Technologies

The latest developments in fiber design and materials science are paving the way for fibers to evolve from parts in passive components to functional parts in active fabrics. Designing conformable, organic electrochemical transistor (OECT) structures using poly(3,4-ethylenedioxythiophene):polystyrene sulfonate (PEDOT:PSS) fibers has excellent potential for low-cost wearable bioelectronics, bio-hybrid devices, and adaptive neuromorphic technologies. However, to achieve high-performance, stable devices from PEDOT:PSS fibers, approaches are required to form electrodes on fibers with small diameters and poor wettability, that leads to irregular coatings. Additionally, PEDOT:PSS-fiber fabrication needs to move away from small batch processing to roll-to-roll or continuous processing. Here, it is shown that synergistic effects from a superior electrode/organic interface, and exceptional fiber alignment from continuous processing, enable PEDOT:PSS fiber-OECTs with stable contacts, high µC* product (1570.5 F cm-1 V-1 s-1 ), and high hole mobility over 45 cm2 V-1 s-1 . Fiber-electrochemical neuromorphic organic devices (fiber-ENODes) are developed to demonstrate that the high mobility fibers are promising building blocks for future bio-hybrid technologies. The fiber-ENODes demonstrate synaptic weight update in response to dopamine, as well as a form factor closely matching the neuronal axon terminal.

Template-Free and Stretchable Conductive Fiber with a Built-In Helical Structure for Strain-Insensitive Signal Transmission

With the rapid development of intelligent electronic devices, conductive fibers have become very critical to signal transmission devices. However, metal-based rigid conductive wires, such as high-modulus copper and silver wires, are prone to signal failure owing to tensile breakage under large strain conditions. Therefore, strain-insensitive stretchable conductive fibers for signal transmission are critical for next-generation wearable devices. Herein, a stretchable conductive fiber with a built-in helical structure is constructed by a "speed discrepancy" fiber-coating strategy with mass scalable production (60 cm/min). Such a "speed discrepancy" strategy is the key mechanism to template-free fabricate a built-in helical structure of the stretchable conductive fiber. The resultant fiber exhibits high conductivity (873 S/cm), stable insensitive signal transmission with a high quality factor (47.4), and a low relative resistance change (∼6%) under large strain. The built-in helical structure inspired by loofah whiskers endows the fiber with excellent strain insensitivity, and it can withstand large strains. On the proof of concept, our fiber can be seamlessly knitted, woven, and braided into smart textiles as an ideal signal transmission device under large strains, which will undoubtedly promote the development of intelligent electronic textiles and next-generation wearable devices.

Magnetically Actuated Fiber-Based Soft Robots

Broad adoption of magnetic soft robotics is hampered by the sophisticated field paradigms for their manipulation and the complexities in controlling multiple devices. Furthermore, high-throughput fabrication of such devices across spatial scales remains challenging. Here, advances in fiber-based actuators and magnetic elastomer composites are leveraged to create 3D magnetic soft robots controlled by unidirectional fields. Thermally drawn elastomeric fibers are instrumented with a magnetic composite synthesized to withstand strains exceeding 600%. A combination of strain and magnetization engineering in these fibers enables programming of 3D robots capable of crawling or walking in magnetic fields orthogonal to the plane of motion. Magnetic robots act as cargo carriers, and multiple robots can be controlled simultaneously and in opposing directions using a single stationary electromagnet. The scalable approach to fabrication and control of magnetic soft robots invites their future applications in constrained environments where complex fields cannot be readily deployed.

Tapered Drug delivery, Optical stimulation, and Electrophysiology (T-DOpE) probes reveal the importance of cannabinoid signaling in hippocampal CA1 oscillations in behaving mice

Understanding the neural basis of behavior requires monitoring and manipulating combinations of physiological elements and their interactions in behaving animals. Here we developed a thermal tapering process (TTP) which enables the fabrication of novel, low-cost, flexible probes that combine ultrafine features of dense electrodes, optical waveguides, and microfluidic channels. Furthermore, we developed a semi-automated backend connection allowing scalable assembly of the probes. We demonstrate that our T-DOpE ( T apered D rug delivery, Op tical stimulation, and E lectrophysiology) probe achieves in a single neuron-scale device (1) high-fidelity electrophysiological recording (2) focal drug delivery and (3) optical stimulation. With a tapered geometry, the device tip can be minimized (as small as 50 μm) to ensure minimal tissue damage while the backend is ~20 times larger allowing for direct integration with industrial-scale connectorization. Acute and chronic implantation of the probes in mouse hippocampus CA1 revealed canonical neuronal activity at the level of local field potentials and spiking. Taking advantage of the triple-functionality of the T-DOpE probe, we monitored local field potentials with simultaneous manipulation of endogenous type 1 cannabinoid receptors (CB1R; via microfluidic agonist delivery) and CA1 pyramidal cell membrane potential (optogenetic activation). Electro-pharmacological experiments revealed that focal infusion of CB1R agonist CP-55,940 in dorsal CA1 downregulated theta and sharp wave-ripple oscillations. Furthermore, using the full electro-pharmacological-optical feature set of the T-DOpE probe we found that CB1R activation reduces sharp wave-ripples (SPW-Rs) by impairing the innate SPW-R-generating ability of the CA1 circuit.

Piezoelectric fibers for flexible and wearable electronics

Flexible and wearable electronics represent paramount technologies offering revolutionized solutions for medical diagnosis and therapy, nerve and organ interfaces, fabric computation, robot-in-medicine and metaverse. Being ubiquitous in everyday life, piezoelectric materials and devices play a vital role in flexible and wearable electronics with their intriguing functionalities, including energy harvesting, sensing and actuation, personal health care and communications. As a new emerging flexible and wearable technology, fiber-shaped piezoelectric devices offer unique advantages over conventional thin-film counterparts. In this review, we survey the recent scientific and technological breakthroughs in thermally drawn piezoelectric fibers and fiber-enabled intelligent fabrics. We highlight the fiber materials, fiber architecture, fabrication, device integration as well as functions that deliver higher forms of unique applications across smart sensing, health care, space security, actuation and energy domains. We conclude with a critical analysis of existing challenges and opportunities that will be important for the continued progress of this field.

Scalable Fabrication of MXene-PVDF Nanocomposite Triboelectric Fibers via Thermal Drawing

In the data-driven world, textile is a valuable resource for improving the quality of life through continuous monitoring of daily activities and physiological signals of humans. Triboelectric nanogenerators (TENG) are an attractive option for self-powered sensor development by coupling energy harvesting and sensing ability. In this study, to the best of the knowledge, scalable fabrication of Ti₃ C₂ T_x MXene-embedded polyvinylidene fluoride (PVDF) nanocomposite fiber using a thermal drawing process is presented for the first time. The output open circuit voltage and short circuit current show 53% and 58% improvement, respectively, compared to pristine PVDF fiber. The synergistic interaction between the surface termination groups of MXene and polar PVDF polymer enhances the performance of the fiber. The flexibility of the fiber enables the weaving of fabric TENG devices for large-area applications. The fabric TENG (3 × 2 cm² ) demonstrates a power density of 40.8 mW m^-2 at the matching load of 8 MΩ by maintaining a stable performance over 12 000 cycles. Moreover, the fabric TENG has shown the capability of energy harvesting by operating a digital clock and a calculator. A distributed self-powered sensor for human activities and walking pattern monitoring are demonstrated with the fabric.

Stretchable conductors for stretchable field-effect transistors and functional circuits

Stretchable electronics have received intense attention due to their broad application prospects in many areas, and can withstand large deformations and form close contact with curved surfaces. Stretchable conductors are vital components of stretchable electronic devices used in wearables, soft robots, and human-machine interactions. Recent advances in stretchable conductors have motivated basic scientific and technological research efforts. Here, we outline and analyse the development of stretchable conductors in transistors and circuits, and examine advances in materials, device engineering, and preparation technologies. We divide the existing approaches to constructing stretchable transistors with stretchable conductors into the following two types: geometric engineering and intrinsic stretchability engineering. Finally, we consider the challenges and outlook in this field for delivering stretchable electronics.

Stretchable One-Dimensional Conductors for Wearable Applications

Continuous, one-dimensional (1D) stretchable conductors have attracted significant attention for the development of wearables and soft-matter electronics. Through the use of advanced spinning, printing, and textile technologies, 1D stretchable conductors in the forms of fibers, wires, and yarns can be designed and engineered to meet the demanding requirements for different wearable applications. Several crucial parameters, such as microarchitecture, conductivity, stretchability, and scalability, play essential roles in designing and developing wearable devices and intelligent textiles. Methodologies and fabrication processes have successfully realized 1D conductors that are highly conductive, strong, lightweight, stretchable, and conformable and can be readily integrated with common fabrics and soft matter. This review summarizes the latest advances in continuous, 1D stretchable conductors and emphasizes recent developments in materials, methodologies, fabrication processes, and strategies geared toward applications in electrical interconnects, mechanical sensors, actuators, and heaters. This review classifies 1D conductors into three categories on the basis of their electrical responses: (1) rigid 1D conductors, (2) piezoresistive 1D conductors, and (3) resistance-stable 1D conductors. This review also evaluates the present challenges in these areas and presents perspectives for improving the performance of stretchable 1D conductors for wearable textile and flexible electronic applications.

Elastic Fibers/Fabrics for Wearables and Bioelectronics

Wearables and bioelectronics rely on breathable interface devices with bioaffinity, biocompatibility, and smart functionality for interactions between beings and things and the surrounding environment. Elastic fibers/fabrics with mechanical adaptivity to various deformations and complex substrates, are promising to act as fillers, carriers, substrates, dressings, and scaffolds in the construction of biointerfaces for the human body, skins, organs, and plants, realizing functions such as energy exchange, sensing, perception, augmented virtuality, health monitoring, disease diagnosis, and intervention therapy. This review summarizes and highlights the latest breakthroughs of elastic fibers/fabrics for wearables and bioelectronics, aiming to offer insights into elasticity mechanisms, production methods, and electrical components integration strategies with fibers/fabrics, presenting a profile of elastic fibers/fabrics for energy management, sensors, e-skins, thermal management, personal protection, wound healing, biosensing, and drug delivery. The trans-disciplinary application of elastic fibers/fabrics from wearables to biomedicine provides important inspiration for technology transplantation and function integration to adapt different application systems. As a discussion platform, here the main challenges and possible solutions in the field are proposed, hopefully can provide guidance for promoting the development of elastic e-textiles in consideration of the trade-off between mechanical/electrical performance, industrial-scale production, diverse environmental adaptivity, and multiscenario on-spot applications.

A 'Moore's law' for fibers enables intelligent fabrics

Fabrics are an indispensable part of our everyday life. They provide us with protection, offer privacy and form an intimate expression of ourselves through their esthetics. Imparting functionality at the fiber level represents an intriguing path toward innovative fabrics with a hitherto unparalleled functionality and value. The fiber technology based on thermal drawing of a preform, which is identical in its materials and geometry to the final fiber, has emerged as a powerful platform for the production of exquisite fibers with prerequisite composition, geometric complexity and control over feature size. A 'Moore's law' for fibers is emerging, delivering higher forms of function that are important for a broad spectrum of practical applications in healthcare, sports, robotics, space exploration, etc. In this review, we survey progress in thermally drawn fibers and devices, and discuss their relevance to 'smart' fabrics. A new generation of fabrics that can see, hear and speak, sense, communicate, harvest and store energy, as well as store and process data is anticipated. We conclude with a critical analysis of existing challenges and opportunities currently faced by thermally drawn fibers and fabrics that are expected to become sophisticated platforms delivering value-added services for our society.