Design and Reliability of Transcutaneous Electrical Neural Stimulation (TENS) Embroidered Electrodes

This research aimed to verify embroidery parameters for manufacturing high-performance dry transcutaneous electrical neural stimulation (TENS) electrodes for future applications in soft-good end products. The embroidery parameters were verified by measuring and calculating surface resistance and signal-to-noise values for manufactured electrodes. Parameters explored in this study included different conductive threads, stitch patterns, stitch densities, and fabric grain-to-stitch orientations, using a Melco ® Amaya Bravo Single Head 16 Needle Embroidery Machine. The chosen embroidery parameters were guided by Goncu Berk’s work in “Design of a wearable pain management system with embroidered TENS electrodes.” An additional aim of the study was to measure the performance of developed e-broidery TENS electrode samples after laundering stresses, following AATCC Test Method 61. The surface resistivity and signal-to-noise values of e-broidered electrodes were measured pre- and post-laundering. The surface resistivity values were again measured and compared to the pre-laundering data. Findings support that core-spun conductive thread stitched parallel to the bias grain is recommended for longevity and reduced impact of laundering. This study of embroidered TENS electrode performance provided crucial insight into better understanding life span and viability as a future “smart” medical wearable device.