RWTH, Peter Winandy

Smart Textronics: Adding Function from Fiber to Fabric 9

th November, Munich,

Benjamin Mohr, Volker Lutz, Thomas Gries

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RWTH, Peter Winandy

Fiber based solutions 4 you

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Institut für Textiltechnik Aachen

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4Devisions 400 employees

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Health

ITA

Augsburg

AMIBM

ITA

Academy

aps

GmbH

Building &

living

Energy &

environment

Mobility

Information &

communication

Materials

Production

Knowledge-

Transfer

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RWTH Aachen Campus

RWTH Campus: a new kind of cooperation between industry and university

• Biggest technology campus in Europe

• Establishment of high-tech

companies in 15 different clusters

• Exchange of research results,

staff, other resources

• approx. 4 bill. € investments until 2020

• approx. 10,000 jobs in research

& development

RWTH, Peter Winandy

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Institut für Textiltechnik Aachen

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4International Locations

Geleen/NL

Augsburg/Ger

Istanbul/TR

Suwon/Korea

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i4.0

History

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i4.0 4 dimensions

4 examples

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i4.0 Information - SozioTex

ELSI = ethical, legal and

social implications

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i4.0 Information - SozioTex

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i4.0 Production - SpeedFactory

• Future of Manufacturing - Autonomik 4.0

• Aim:

Production of highly individualized products

Highly flexible production infrastructure

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i4.0 Production - SpeedFactory

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i4.0 Production - SpeedFactory

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i4.0 Knowledge - Textile Learning Factory 4.0

Weaving machine

Warping machine

Warping creel

Light table

Inkjet printer

Coating & thermo-

setting device

Cutting machine

Sewing machine

Testing station

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9 1

2

3 4 5

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Smart,

customizable

wristband

Product Machines

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i4.0 Digital Products – Dream2Lab2Fab

RWTH, Peter Winandy

Digital Products: Smart Textronics - Central components of modern ICT systems

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> 3.000

2026

Forecasts indicate a rapid growth of the smart textile market over the next decade with a potential market size of 3 billion USD by 2026

Source: IDTechEx research

2015

~100

Smart Textiles market size

USD million

CAGR by industry sector based on growth

to 2026 values from the base at 2014

• Key advances in the last

five years have led to

early commercial

products, with a market

of around USD 100 m in

2015

• Forecasts indicate that

the market will reach over

USD 3 bn by 2026 as

larger names enter the

space and manufacturing

costs decrease

• Two largest sectors in

2015 being Sports &

Fitness and Medical &

Healthcare

• Home & Lifestyle has

the largest growth,

mainly due to starting

from a near-zero base

+36% p.a.

0% 20% 40% 60% 80%

Industrial,

Commercial,

Military

Fashion

Other

Sports &

Fitness

Medical &

Healthcare

Wellness

Home &

Lifestyle

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We define Smart Textiles as textiles with integrated functionality

Source: www.smarttextiles.de

Our understanding

• Smart Textiles sense, react

or interact with the

environment by the change

of their physical, chemical

and/or electrical properties

• They are textiles with

advanced functionality

realized by integrating

Electrical components/

circuits (“e-textiles”)

Sensors and actuators

Power supply

Major component groups of Smart Textiles systems

Sensor

Energy

source

Actuator

External

communication

Data

processing

Internal data transfer

Smart Textile System

Smart Textronics

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Product examples for smart textiles include smart clothing, smart beds, sports tracking and many more

Source: IDTechEx research

• Clockwise, from top left

Dreamlux Happiness

blanket

Luna (now known as

Eight) smart bedsheet

Polo/OM Signal

smart shirts

Embroidered and woven

LED lighting clothing

(FRTI)

AiQ smart clothing

Sensoria smart socks

Electronics-integrated

military apparel

Hexoskin smart shirts

Adidas/Clothing+ smart

clothing

Myontec EMG

compression shorts

+ many more examples

Smart

Textiles

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Smart Textiles have developed from textile-adapted to textile-integrated systems – in the future the textile itself will become the electric component

Before Today Tomorrow

Textile and part

textile-adapted

Textile with part

Textile-integrated

Textile is part

Textile-based

ScotteVest

Source: www.smarttextiles.de

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Current state of research and major R&D topics across the smart textronic value chain from material to product and service (1/2)

Design & Product

Development

Yarn

production

Yarn

processing

Textile

processing

Textile

production

Manu-

facturing

Functionalizing yarns1 on material level using fiber and thread production technology (extrusion,

spinning, plying)

Functionalizing yarns1 applying coating technologies

Integrating functionalized yarns into fabrics to keep textile mechanical properties such as

drapeability (knitting, weaving, braiding, sewing)

Adding functional yarns using additive production technologies such as printing and embroidery

Integrating (micro-) electronic components on textile fabric using connection technology (soldering,

adhesive bonding, crimping)

Material &

Components

Fiber material

(Micro-)

electronics

Production

Software

Services

Use of systems, simultaneous, and agile engineering as well as rapid prototyping tools and

techniques such as SCRUM, IREB or MBSE

Developing active fiber materials such as POF, piezoelectric fibers, conductive materials2, chromic

materials3, shape memory materials4, phase change materials5 or inks and encapsulations

Developing operating systems, software products, applications running on

smart textile hardware and SDKs for standardized

Building smart textile enabled services and business models such as platforms,

“as-s-service” models and data driven services

1 to be light transmitting, electrical conductive or piezo electric; 2 metals, conductive polymers, carbon; 3 photo-, thermochromics

textiles; 4 reacting to heat, light or magnetic fields; 5 as latent heat accumulator; 6 such as MEMS, battery technology, sensors (e.g.,

accelerometer, GPS, pressure, gyroscope), microprocessors (CPU/SPU module), data storage; 7 e.g., Bluetooth 4.0; 8 e.g., RFID

Category Description

Developing small, flexible, and robust (micro-)electronic components6, (low power) wireless

communication technology7, and AutoID technology8 to be integrate into textiles

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Current state of research and major R&D topics across the smart textronic value chain from material to product and service (2/2)

Design & Product

Development

Yarn

production

Yarn

processing

Textile

processing

Textile

production

Manu-

facturing

Material &

Components

Fiber material

(Micro-)

electronics

Production

Software

Services

Open innovation and collaborative design process and technology for smart textile product

development (e.g., SDK, platform technology, standardized interfaces)

Brand new types of conductive fibers and yarns, corrosion resistance (washability), carbon

nanotubes (CNT) and graphene, RFID yarns, energy harvesting1, newly developed stretchable inks

Self Development Kits for the Design of individualized services

Smart textile enabled business models such as platforms, “as-s-service” models and data driven

services

1 photo voltaic, piezoelectric (nano-) fibers

Category Major R&D topics

Improvement of performance requirements (e.g., washability, ironing, etc.) as well as design features

(flexibility, size, etc.)

• Process development for scalable smart chemical fiber production (e.g., POF production)

• Integration of conductive fibers into fabric

• Integration of electronics (e.g., logic, memory) in yarns

• Energy harvesting: Piezoelectric fabric

• Energy storage: Textile supercapacitors, flexible woven batteries

• Digital inkjet printing of electrical circuits on fabric

• Flexible and robust joining and bonding technologies for sensor/microelectronics integration onto

textile structures

• Process digitization/Industry 4.0 (e.g., value chain visibility, digital assistant systems, predictive

maintenance, self-optimization)

• Modular, interlinked, flexible process chains for the automated production of smart textiles

• E2E process design (Design, R&D, production planning, manufacturing, logistics, service)

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i4.0 Digital Products – Dream2Lab2Fab

Research center Korea

2 interdisciplinary research Centres for

electronics and production technologies

Research center Germany

Development of processes,

value chains and smart

services

Business Model (Smart Services)

Science Industry

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... companies

about new

applications &

technologies

and how they

can profit from

these new

solutions

… state-of

the-art appli-

cations &

technologies

of leading

manufac-

tures

… industry

experts and

managers in

extensive

training pro-

grams; build

“internal”

capabilities

at scale

Transformation Center (Textile Lernfabrik 4.0) Innovation Factory (D2L2F)

Cross-industry R&D projects in the field of smart

production of smart (textile) products

Real-life demonstration & learning environment to

transfer research results into broad industry practice

Product Development & Design

Software

Services

Materials & Components

Production (automation & digitization)

Lifestyle &

Sports Health

Automotive

& Aerospace

Building &

Infrastructure

Requirements

& specifications

Latest

innovations

… the transforma-

tion & generate

lasting impact with

the support of

experienced

consultants and

the learning factory

as an accelerator

for building internal

capabilities

A B

Textile Innovation & Transformation Center

Inform Demon-

strate Qualify Kick-start

Develop prototypes for innovative products,

services, and technologies

Accelerate industry deployment of new

technologies

We are therefore setting up a world class innovation and trans-formation center for the smart production of smart textile products

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Textile Innovation & Transformation Center

• Dream2Lab2Fab

RWTH, Peter Winandy

Smart Textronics: Adding Function from Fiber to Fabric

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Optical yarn in spacer fabric LED on textile Luminous effect

realized by

hybrid structure

Smart Textronics: Textile illumination of interiors and clothing

Use of different lighting components

• Active lighting (organic and inorganic LEDs, luminescent yarn)

• Passive lighting (optical conductor, fluorescent and phosphorescent material)

Extensive and on the spot illumination

Construction of composite structures for lighting textiles

Integration of sensors for the control of the lighting

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Smart Textronics: Textile illumination of interiors and clothing

New raw

materials

• New polymer

optical fibers

TPU

PMMI

Biobased

PC

New

functionalization

• Sidelight fibers

Surfacetreatme

nt

Scattering

particles

Textile Integration

• Weaving

• Knitting

Tranluscent Composites

• Wood surface

wooden haptic

Wooden optic

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Smart Textronics: For Heating Applications

Heating materials

• Stainless steel yarn

• Silver coated polyamide yarn

• Copper strands

• PTC material

• Isolated/ non isolated

• Nanomodified Yarns

Production process

• Tailored Fiber Placement

• Knitwear

• Weaving

• Printing processes

e. g. Thermo sensors

• Usage of yarn with different thermoelectric

voltage

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Smart Textronics: Interface between textile and user

Transmitting materials

• Electrical conductive yarns

Nanomodified fibers

Coated fibers

• Optical fibers

Glass fibers

Polymer optical fibers

Transmitting textiles

• Coating

• Contacting

Printing

Embroidery

Concepts of interaction with textile

• Textile switch matrix

• Haptic-intuitive input signal via creases

• Proximity and touch sensor Textile proximity sensor

Input signal via creases

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Smart Textronics: Interface between textile and user

Smart Textronics: Optical textile Touchpad

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4D Textiles – Vision

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4D Textiles – Definition

What are 4D Textiles?

The term „3D Textiles“ has been defined by Wulfhorst et al. in 2000.

4D Textiles are fabrics and textile products being able to change shape and function

over time. This change is achieved by the complex interaction between hybrid

materials and by the use of external stimulus.

Additional to the spatial expansion of fabrics (3D) the change over time faces the

4th dimension in textiles.

Source: BMW Group

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4D Textiles

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i4.0

4D

i4

Information Production

Product Knowledge

The Institute

Future Textiles

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Many Textronic

products made it to

functional

demonstrators. Now, we

have to close the gap to

serial production

4 you.