TEXTILES
BRM to work with them to incorporate these smart textiles into new designs. Without available COTS solutions, development can be extremely challenging because every smart textile design is specific to an application. To develop the proper solution, information is needed on how the textile is to be used, electronic specifications, mechanical connector specifications, and CPU functionality, as well as data storage, retrieval, and security requirements. Each of these elements take significant investment from all stakeholders and technology holders, including the yarn supplier, fabric weaver, computer programmers, and connector technology. None of these elements are open sourced technology – and current intellectual property (IP) protections limit shareability of ideas. To meet the challenge, BRM has formed
informal partnerships with fabricators and OEMs to develop the solution while protecting IP. After establishing clean lines of communication - and using legal documents specifically developed to build trust - BRM has gained “a seat at the table,” and been granted access to protected information. In addition, BRM has made significant
investments in new products without having an end use application - conducting benchtop analysis work with the technology supplier to provide working examples demonstrating how the technology can be applied. Spending money on R&D without having established partners is an unusual strategy for small to medium sized companies with limited budgets, but is considered an essential way of bridging the gap posed by the lack of COTS solutions. Before embarking on projects, BRM has found it important to develop proper NDA agreements and have a clear understanding of IP considerations. BRM’s standard operating procedures now include preparation of a supply and commercialisation agreement that provides a mutual contract to advance technology. It tells its customers: “BRM wants to have machines running and you want to be finishing products and selling to customers.”
Lack of industry standards Smart textiles is a new and rapidly growing field and lacks a complete set of agreed upon standards. BRM is an active member of the IPC Textile forum, which is helping to develop these standards for conductive textiles. For example, as a member of the IPC D-70 E-
Textiles Committee, BRM engineer Joe Geiger has been making significant progress in verifying and validating conductive element properties; assessing and measuring washability; and measuring durability and wear. “Creating a space where both industries
agree on what is required in order to derive more reliable data will help push our ability to create more robust and stable products,” says Geiger. He notes that the work will help the group focus on the data that is most important to this emerging industry, while maintaining the integrity of textile products. The committee recently held a poll in which members answered questions on washability
UKManufacturing Autumn 2022
testing and different product classes to help gain a better understanding of the members’ needs for the standard. The group presented its results and members participated in working groups to better define the parameters or classification of the products being tested. “Having committee members that are not just in the textile field or electronics industry is starting to develop a better understanding of what is needed from both halves of the E- textiles conversation,” Geiger says. “It is pushing these standards forward for the better. The coalescing of these two fields will be more successful if there is a set of unified terminology on our subject matter.”
Development costs The benefits of smart textiles have by and large not yet fully exceeded the costs of development for bringing this technology to the market. Commercial volumes are not yet available to help bring down costs. To overcome this challenge, BRM has been investing to bring the technology to a basic level - and then looking for stakeholders who are willing to invest further because they have a specific application. BRM co-invests in technologies that make
sense. It takes executive level commitment of all third-party stakeholders to bring the new technology to market. BRM has improved its internal communication to the executive level for support and works with the third parties to do the same. Focusing on proper project management and communication through multiple levels of the organisation is helping to keep project funding flowing.
SMART TEXTILE PROJECT EXAMPLES The smart textile field is growing rapidly as companies are gradually overcoming the challenges faced. A few recent examples include:
LED lights providing illumination embedded within a textile BRM is currently working on several interior design and safety applications involving embedding LED technology within a textile – providing illumination while maintaining the tensile structure that enables the textile to perform its original purpose. The applications envisioned include providing illumination for emergency services or visual warning lights. Development work is focusing on integrating the correct connectors and power sources.
Embedded stress and strain sensor In partnership with Luna Innovations, BRM is working on embedding LUNA’s fibre optics technology, which measures mechanical/thermal stress applied to a fibre optic monofilament. Using a laser system to measure changes in the fibre optic, the sensor extracts data to be used for lifecycle monitoring of a finished product or for manufacturing process optimisation. For example, it could be used to measure data and monitor changes to predict potential catastrophic failure in critical components in the oil and gas industry.
The textiles are also currently in the testing and validation stage for use in lifecycle management of inflatable habitats being developed by NASA for use on the moon as a waypoint for the mission to Mars. Embedded stress sensors are also being
developed for the composites industry, which is using them in material to optimise the aircraft manufacturing process for the aerospace industry. In one application under development, data extraction during the manufacturing process will be used to validate the quality of structural airframe components.
Metallic coatings on standard textile fibres Work is being done to bridge the gap between textile performance of new technology and the limiting factors of durability and degradation caused by use and wear. Several companies have successfully applied coating technology to traditional textile yarns, including nylon 6.6, polyester, and aramid: DuPont Kevlar. Current metallic coating development work is utilising such metals as gold, silver, and nickel, especially for applications requiring more than electrical conductivity. For example, BRM is working on applications with customers interested in EMI shielding, electro-magnetic field creation, piezo-resistive capability, and data collection. Many of these coatings are not permanent and BRM partners are developing bonding chemistries to improve their sturdiness. Some are more successful than others. Much of the development is being conducted in collaboration with suppliers and OEMs for developing additional functionality for NASA astronaut personal protective equipment, deep space structures, commercial aircraft, and industrial and wearable applications. As these technologies are further developed, tested, and fielded, BRM expects to learn more about balanced requirements for accommodating the textile’s useful service based on the stability of the coatings over a specified time frame and under varied but specified environmental conditions.
Anti-microbial yarns and finishes Spurred on by the critical need to tackle the presence of the COVID virus on textile surfaces, this new application is focused on adding antimicrobial yarns and antimicrobial finishes to kill bacteria and viruses, speeding up product cleanup time. The new material would kill a virus that lands on the textile within 30 seconds, rather than minutes it typically takes now. The work is being done for several public transportation and medical applications.
CAPTURING THE PROMISE Demand is growing for smart textiles that can measure and monitor health, increase productivity, and improve functionality. Now smart textile manufacturers have to move forward with the research and development that will capture the promise of these new materials.
Bally Ribbon Mills
www.ballyribbon.com
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