Electrical and Draping Performance of 3D-Printed Conductive Composites Integrated with Textile Fabric 


Vol. 26,  No. 11, pp. 4993-5005, Nov.  2025
10.1007/s12221-025-01137-2


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  Abstract

In the current field of wearable technology, silver yarns are used to provide electrical conductivity to non-conductive textile fabrics required for monitoring and measurement. This work aims to provide an alternative to silver yarn by exploring innovative methods to integrate 3D-printed circuitry onto textile fabrics to offer an ideal solution for prototyping textile-based wearable technology products. For the first time, different conductive composite filaments were investigated for both improved electrical conductivity and drapability. Specimens were fabricated by 3D printing electrically conductive material on a textile fabric between two disconnected squares made of knitted silver yarn. Electrical conductivity and drapability were two design objectives. 3D printed samples were made from off-the-shelf conductive composite filaments: two carbon black/PLA filaments and one copper/polyester filament. All samples are manufactured using a Material Extrusion 3D printer. The impact of trace patterns, width, and thickness on electrical conductivity on a hard surface and textile fabric was evaluated along with drapability. The copper/polyester trace integrated onto the textile through 3D printing was found to have electrical and draping performance similar to the reference textile fabric made with silver yarn. The S-pattern geometry with a 2.5 mm trace radius, 4 mm width, and 1.5 mm thickness was best for electrical performance, possessing a resistance of 3.58 Ω/cm and draping coefficients of 45.3% along the trace and 61.1% across the trace. The S-pattern geometry with the same width and thickness, but a 5 mm trace radius, exhibited a slightly higher resistance of 4.76 Ω/cm but lower draping coefficients of 35.8% and 57.7% along and across the trace, respectively. This made it a better choice for applications where enhanced drapability is critical.

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  Cite this article

[IEEE Style]

R. Solmon and K. Fayazbakhsh, "Electrical and Draping Performance of 3D-Printed Conductive Composites Integrated with Textile Fabric," Fibers and Polymers, vol. 26, no. 11, pp. 4993-5005, 2025. DOI: 10.1007/s12221-025-01137-2.

[ACM Style]

R. Solmon and K. Fayazbakhsh. 2025. Electrical and Draping Performance of 3D-Printed Conductive Composites Integrated with Textile Fabric. Fibers and Polymers, 26, 11, (2025), 4993-5005. DOI: 10.1007/s12221-025-01137-2.

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