Revolutionizing Combat Training: Harnessing E-Textile Technology for Optimal Performance

On June 25, Professor Steve Park’s team at KAIST’s Department of Materials Science and Engineering unveiled a revolutionary flexible electronic textile (E-textile) platform utilizing cutting-edge technology to directly embed electronic circuits onto fabric. The research findings have been published in the journal npj Flexible Electronics.

This wearable e-textile platform integrates 3D printing technology with innovative materials engineering design to print sensors and electrodes directly onto textile substrates. This enables the precise collection of movement and physiological data from individual soldiers, facilitating the development of personalized training models.

Previous e-textile fabrication methods often faced complexity or limitations in customization. To overcome these challenges, the research team adopted Direct Ink Writing (DIW) 3D printing, an additive manufacturing technology.

DIW involves dispensing special ink, serving as sensors and electrodes, directly onto textile substrates in desired patterns. This allows for flexible design implementation without the need for intricate mask fabrication. This technology is poised to be easily deployable to hundreds of thousands of military personnel.

The essence of this technology lies in the development of high-performance functional inks derived from advanced materials engineering. The research team combined styrene-butadiene-styrene (SBS) polymer, offering flexibility, with multi-walled carbon nanotubes (MWCNT) for electrical conductivity.

They formulated a tensile/bending sensor ink capable of stretching up to 102% while maintaining stable performance even after 10,000 repetitive tests. This ensures the consistent acquisition of accurate data, even during the rigorous movements of soldiers.

Moreover, novel material technology was implemented to create “interconnect electrodes” that establish electrical connections between the upper and lower fabric layers. The team developed an electrode ink by combining silver (Ag) flakes with rigid polystyrene (PS) polymer, precisely regulating the impregnation level to effectively connect multiple fabric layers. This innovation paves the way for producing multi-layered wearable electronic systems integrating sensors and electrodes.

The research team validated the platform’s performance through real-time human movement monitoring experiments. They embedded the e-textile on key joint areas of clothing (shoulders, elbows, knees) and monitored movements and posture changes during various exercises like running, jumping jacks, and push-ups.

Additionally, they showcased the potential for applications such as monitoring breathing patterns using a smart mask, object recognition through machine learning, and interpreting complex tactile information by embedding multiple sensors and electrodes on gloves. These findings underscore the efficacy of the developed e-textile platform in accurately deciphering soldiers’ movement dynamics.

This research serves as a significant example of how state-of-the-art material technology can advance the defense sector. Major Kyusoon Pak from the Army, involved in this study, emphasized the importance of military applicability and economic feasibility for practical deployment right from the research design phase.

Major Pak expressed, “Our military is currently facing challenges and opportunities due to dwindling personnel resources caused by demographic shifts and technological advancements. The emphasis on preserving lives on the battlefield has become a crucial concern.”

“This research aims to establish unique technology capable of delivering tailored training based on military branch, duty, and combat type, thereby enhancing combat effectiveness and safeguarding our soldiers’ survivability.”

He concluded, “I anticipate that this research will be acknowledged as a case study that achieves both scientific significance and military utility.”