An automated process for inclusion of package dies and circuitry within a textile yarn

The integration of small electronic components into textile fabrics, without compromising the textile qualities such as flexibility and conformability, is necessary in ensuring wider adoption of electronic textiles. A solution is to use flexible, electronic yarns that incorporate electronic components within the fibers of the yarn. The production of these novel yarns was initially a craft skill, with inclusion of electronics within each section of yarn taking 60 - 90 minutes. A prototype, automated production process was developed to speed up the manufacturing process to 6 minutes. This paper describes the process, using machinery and methods from both electronics and textiles applications.