Smart Textiles Offer Development Opportunities In Medical, Health Applications

SensorsSensoriaSock
Redmond, Wash.-based Sensoria developed a smart sock that could monitor not only how fast and far a runner went, but also how well they run.

The medical field benefits from textile innovations, and the rapid development of sensor technology brings new products to the healthcare and wellness market.

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The textile news has presented a number of stories centered in and around the medical industry in recent months. Whether the news relates to implantables and grafts, coatings and additives for wellness and bacteria protection, or innovative uniform fabrics, the textile industry is playing a role in medical progress. One particular area of note is sensor technology. Rapid development is taking place in the sensor market, and many companies are developing smart textile products for medical and health-related applications.

Making Socks Smart

Recently, San Francisco-based health technology company Siren introduced Neurofabric™, a Diabetic Sock and Foot Monitoring System that features microsensors embedded directly into the fabric. Six sensors — three across the ball of the foot, one in the arch and one on the heel — continuously monitor foot temperature looking for variation.

According to the company, Siren Diabetic Socks continuously monitor foot temperature to help detect signs of inflammation, the precursor to diabetic foot ulcers. Monitoring foot temperature is clinically proven to be the most effective way of catching foot injuries, and is up to 87-percent more effective at preventing diabetic foot ulcers than standard diabetic foot care.

Neurofabric™, a Diabetic Sock and Foot Monitoring System developed by San Francisco-based Siren, features six microsensors that continuously monitor foot temperature, looking for variation.
Neurofabric™, a
Diabetic Sock and Foot Monitoring
System developed by San Francisco-based Siren, features six microsensors
that continuously monitor foot
temperature, looking for variation.

The company reports that approximately 56 percent of diabetic foot ulcers become infected, and 20 percent of those people with infected foot wounds end up with some type of lower extremity amputation. More than 100,000 legs are lost to diabetes each year in the United States. Meanwhile, up to 80 percent of people with diabetes who have foot amputations pass away within five years.

The socks wearer can see the temperature of their feet instantly with the app and compare changes from day to day.

“We built this technology because foot ulcers are the most common, costly and deadly complication for people with diabetes, yet there was no way to continuously monitor for these massive problems,” said Ran Ma, CEO and co-founder of Siren. “Our Neurofabric has endless applications across healthcare, sports, military, and fashion, but it was obvious to us that solving this specific problem is where we had to start, because it impacts so many and can mean the difference between losing a limb or not.”

The socks are sold as part of a system, which is offered as a subscription that includes five pairs of new Siren Diabetic Socks shipped every six months, the Siren Companion App, and live customer support.

Siren Diabetic Socks feature:

  • Neurofabric™ — Seamlessly-integrated sensors that monitor foot temperature at six key points — the most effective method for determining foot health;
  • Comfortable fit — All socks are seamless and non-binding;
  • Machine-washability and don’t need charging; and
  • Moisture-wicking — Fabric removes moisture from the foot area to promote healthy skin.

Six months is the expected useful life of the embedded battery.

According to Siren, for people with diabetic neuropathy the socks look and feel just like a regular pair of socks and provide continuous, clinical-grade temperature monitoring and health tracking over time. All they have to do is put on their socks like they would any other day.

Printed Graphene Sensors

Newark, Del.-based W. L. Gore & Associates and Bonbouton, New York City, have entered into a joint development agreement “to explore material solutions in advanced sensor technology and enable practical smart fabrics for assistive apparel and digital health applications.”

Bonbouton — a manufacturer of inkjet-printed, low-cost graphene temperature sensors — licensed technology developed at the Stevens Institute of Technology, Hoboken, N.J. The company’s flexible and molecularly thin sensors made using graphene oxide (GO) can be used for monitoring skin temperature.

The Bonbouton-Gore partnership will initially focus its research on temperature sensing technology and “will lay a foundation for future applications of sensor technology and conductive inks in digital health, chronic care management and smart fabrics.” The companies will utilize the Gore Innovation Center and are equal partners. Gore’s Innovation Center houses a prototyping facility where various developers and corporations can innovate and collaborate, while Gore can move forward its mission to provide support and assistance for start-ups in the digital health arena.

“Our work with Gore, and specifically the Innovation Center, is an exciting development,” said Linh Le, CEO and founder, Bonbouton. “Its materials and expertise are what will allow us to improve on existing technology and take development to the next level. Gore is known for a science-backed approach to comfort and wearability. Coupled with its collaborative resources and exploratory mindset, this makes Gore a model partner.”

“Because of its extraordinary flexibility and thinness, we envision that ‘comfortable-to-wear’ graphene sensor arrays can be used for constant and wireless monitoring of a variety of pathophysiological developments,” Le said.

“We are thrilled to be working with Bonbouton to explore our combined potential, especially in applications where it can enhance quality of life for those with chronic conditions,” said Linda Elkins, co-leader, Gore Innovation Center. “The Gore Innovation Center offers a prototyping facility where startups, researchers, customers and corporations can collaborate and innovate.”

San Francisco-based Emglare introduced smart clothes designed with sensors for monitoring heartbeat as well as the electrical activity of the heart using electrocardiography (ECG).
San Francisco-based Emglare introduced smart clothes designed with sensors for monitoring heartbeat as well as the electrical activity of the heart using electrocardiography (ECG).

Built-in ECG And Heart Rate

Recently San Francisco-based Emglare introduced smart clothes designed with sensors for monitoring heartbeat as well as the electrical activity of the heart using electrocardiography (ECG). Emglare’s smart clothes communicate directly with a mobile phone application where all monitored health information is made available.

Emglare’s first commercial product is the Emglare Heart mobile application, which is compatible with its smart clothes featuring built-in ECG and heart rate sensors. The clothing can be recharged directly using a wireless charger. The company initially has designed an undershirt and sports T-shirt for men, and a sports bra and regular bra for women. According to the company, the products are suitable for daily use because one of the its goals was “to produce smart clothes that are natural and comfortable even when worn all day.”

“Our goal is to create the best smart clothes in the world that are not only super smart but mainly comfortable and suitable for everyday wearing,” said Jifií Pastor, CEO and founder of Emglare. “Our products are developed by a group of specialists from different disciplines – healthcare, informatics and fashion industry.”

Sensoria has recently extended its sensor technology into the Sensoria Smart Running Shoe.
Sensoria has recently extended its
sensor technology into the Sensoria Smart Running Shoe.

Sensoria For Health, Wellness

Several years ago, Redmond, Wash.-based Sensoria introduced a smart sock that could monitor not only how fast and far a runner went, but also how well they run. The right and left footed socks feature three sensors under the plantar area of the foot to detect foot pressure. The sensors are connected to conductive fibers in the sock that can relay data collected to an anklet that is connected to the sock’s cuff via a magnetic attachment. Sensoria reports the sock was designed to act as a textile circuit board. The lightweight anklet is activated when connected to the magnetic attachment and communicates continuously with a Sensoria mobile app using Bluetooth Smart. The company also makes upper garments that can monitor heart rate.

More recently, the company has extended this technology into the Sensoria Smart Running Shoe. Textile pressure sensors embedded in the shoe are connected to a detachable electronic device called Sensoria® Core, which features system on chip (SoC) technology. The sensors monitor pace, speed, ascent and descent, cadence, contact time, foot-landing technique and impact, which is accessed using the Sensoria Run companion app. A runner may use the data to improve performance and reduce the risk of injuries. Sensoria currently is taking preorders for the shoes.

Sensoria reports its technologies are customizable and compatible with a variety of healthcare applications. Its sensors are safe for use on skin and have been tested at a variety of pH ranges. The thin sensor — less than 1 millimeter thick — offers flexibility for a wide range of clinical applications including diabetic foot complications, fall detection and prevention, neurology, and rehabilitation, according to the company.

BeBop: From Musical Applications To Health Tech

Berkley, Calif.-based BeBop Sensors Inc.’s approach uses fabric to measure force. Launched back in 2014, BeBop’s Wearable Smart Fabric Sensor was developed as a spin off from a sensor technology company created by musical instrument inventor Keith McMillen. BeBop uses a combination of polymers to make a fabric piezoresistive. When the material is strained in any way — twisted, bent, stretched or when force is applied — there is a change to the fabric’s electrical properties, which can be quantified by conductive inks that sense the change in resistance. Unique geometries are used depending on the application.

According to the company, its sensors can measure physicality, XYZ location, bend, motion, rotation, angle torsion as well as sense pressure. BeBop reports the market applications for its technology include clothing and protective wear, shoes, healthcare devices, athletic equipment, automotive, robotics, aerospace, gaming, biometrics, and prosthetics.

Conductive inks sense changes in resistance in Berkley, Calif.-based BeBop Sensors Inc.’s piezoresistive fabrics. Unique geometries are used for each application.
Conductive inks sense changes in resistance in Berkley, Calif.-based BeBop Sensors Inc.’s piezoresistive fabrics. Unique geometries are used for each application.

The company developed a High Resolution Smart Helmet Sensor System, which employs 40 sensors in the helmet’s liner to capture a high-speed movie of an entire impact incident from the perspective of the head. The data, which includes the exact impact location and velocity thresholds, can be used by first responders and for post-trauma analysis. The helmet also can be programmed to trigger an emergency call or other response command. “Strikes to the pterion (temple area) are far more dangerous than to the frontal bone, said Keith McMillen, BeBop founder and CEO. “Knowing where the strike originated and how it propagates during the event can provide valuable first responder information as well as input for decision making to dial an emergency 911 number for assistance.”

Recently, the company closed a more than $10 million Series A round of funding led by San Francisco-based Bullpen Capital. The company reports it intends to use the funds to accelerate product development and market penetration of its sensor-based technologies.

July/August 2018

Georgia-Pacific To Sell European Nonwovens Business

Atlanta-based Georgia-Pacific LLC has agreed to sell its Georgia-Pacific Steinfurt GmbH nonwovens business to York, Pa.-based Glatfelter for $185 million. The deal is subject to customary closing conditions and regulatory clearance from competition authorities.

The proposed deal includes Georgia-Pacific’s European airlaid nonwovens operations in Steinfurt, Germany, as well as sales offices in France and Italy. Once the deal closes, the approximately 220 Steinfurt employees will become Glatfelter associates.

The deal does not impact any of Georgia-Pacific’s U.S.-based nonwovens businesses including the nonwovens research and development center in Memphis, and operations in Mt. Holly, N.C. and Green Bay, Wis.

“Georgia-Pacific nonwovens employees in Steinfurt have done a great job running a safe and productive operation, and have worked hard to make significant improvements to meet European customer needs,” said Doug Dowdell, president – nonwovens, Georgia-Pacific. “We believe this sale to Glatfelter, an established manufacturer with multiple European operations, is in the best interests of customers and Georgia-Pacific Steinfurt GmbH employees.”

July/August 2018

Crown Capital Acquires Graniteville Specialty Fabrics

Atlanta-based Crown Capital Investments LLC has acquired Graniteville Specialty Fabrics (GSF), Graniteville, S.C., a producer and distributor of highly engineered coated products used for such items as military shelters, marine covers and tents. GSF will remain in Graniteville, where the company has approximately 17 acres with offices, manufacturing and onsite research facilities.

“Graniteville is a great company and our families are thrilled with the acquisition,” said Christopher Graham, CEO, Crown Capital Investments. “We focus on investing in well-established, market-leading companies and helping them optimize operations, innovate and grow over time. The brand, the products and the management team all demonstrate the high performance attributes we seek within our portfolio companies.”

“Graniteville Specialty Fabrics has been known for quality products and innovation for over 70 years,” said Jim Egan, president, Graniteville Specialty Fabrics. “We’re excited to be associated with Crown Capital. Throughout the process Crown Capital was the obvious choice of our management team.”

July/August 2018

Avgol Invests In Waveform 3D™ Technology

Israel-based Avgol is launching Waveform 3D™ technology, a new 3-D concept for fabrics used in hygiene applications. The Waveform process allows nonwovens used for diapers, adult incontinence and feminine hygiene products to be modified with distinctive surface
patterns with varying 3-D profiles. Avgol reports the 3-D fabric composition can impart additional benefits including skin wellness, cushioning and an enhanced cotton feel.

“Investment in Waveform 3D Technology enables Avgol to offer high-performance nonwoven fabrics without compromising comfort,” said Nick Carter, director, Market Business Intelligence and Intellectual Property, Avgol. “The ability to choose whether to use solid, apertured or combination patterns allows the product designer to truly tailor a solution for their application including how the fabric feels, how the fabric functions and how the fabric looks.

“Waveform 3DTechnology is part of an exciting program of novel solutions to meet the ever-evolving regional needs of our customers and deliver added value through leading-edge developments, quality and service.”

July/August 2018

Lenzing Introduces VEOCEL™ Brand For Nonwovens

The Lenzing Group, Austria, has introduced VEOCEL™, a nonwoven specialty brand of nonwoven fibers. Veocel fibers are certified as clean and safe, biodegradable, of botanic origin and produced in an environmentally responsible manner. Veocel fibers — including Veocell Lyocell and Veocel Specialty Viscose Fibers derived from renewable or sustainable wood sources from certified and controlled forests — can be used in a variety of everyday applications including baby care, beauty and body care and surface cleaning, and applications are grouped in branded offers as Veocel Beauty, Veocel Body, Veocel Intimate and Veocel Surface. The introduction is part of Lenzing’s new brand strategy to transform from a business-to-business fiber producer to a business-to-business-to-consumer brand.

“Guided by our sCore TEN strategy, the launch of the Veocel brand will accelerate our migration into a specialty fiber business with a strong focus on innovation, quality and sustainability,” said Robert van de Kerkhof, chief commercial officer, Lenzing Group. “Through ongoing proactive communication, the Veocel brand will also promote a holistic understanding about the benefits of botanic fibers in nonwoven products across the industry value chain and among consumers.”

July/August 2018

Dixie Color To Form Dixie Specialty Fibers

Dixie Color Inc., Trion, Ga., has announced it will invest $19 million to establish Dixie Specialty Fibers in Trion. The expansion will create 100 new jobs in production, management, supervisor, technician and administrative roles. Dixie Color specializes in single pigment dispersions, custom color masterbatches and plastic compounding. The addition in Trion is to aid development of a new polyethylene terephthalate microfiber product for bath mats, area rugs and carpet;and support the demands of the fine denier microfiber market.

“Will Dendy and I started Dixie Color in 2009 with the vision of being a full-service color supplier to the tremendous growth of the solution-dyed flooring industry,” said Lee Starks, vice president of Dixie Color. “The formation of Dixie Specialty Fibers is representative of our commitment to continue to reinvest our resources into our employees, community, and customer base. We are excited to be the first local domestic supplier of microfiber, and we are even more excited about the opportunities it will create for our existing and future employees, as well as continuing to meet our customers’ needs.”

July/August 2018

Loop Industries Working To Commercialize Technology

Loop Industries, Terrebonne, Quebec, is designing a fully integrated manufacturing facility to upcycle waste polyester (PET) and PET fiber into virgin quality Loop™ PET resin and polyester fiber. Loop reports the move is the next step in commercializing its Generation II technology. Coupled with Loop’s proprietary depolymerization technology, the state-of-the-art PET production processes allow plastic waste to be used as feedstock to manufacture Loop PET resin. The process separates the PET from all contaminants — including colors, dyes or additives — and recycles waste PET and polyester fiber in any form or condition into virgin quality Loop PET resin and fiber. This integrated manufacturing model will form the basis of the company’s commercialization strategy.

“A fully integrated start-to-finish process will soon exist to commercialize Loop’s innovative Generation II technology and help tackle the global plastic crisis,” said Daniel Solomita, CEO and Founder of Loop. “These facilities will make it possible for all forms of waste PET and polyester fiber, even ocean plastics that have been degraded by the sun and saltwater, to be fully recovered and upcycled into PET of the highest purity and performance quality.”

July/August 2018

CSU Chemists Derive Biorenewable Plastic Alternative

A team of Colorado State University (CSU) polymer chemists led by professor Eugene Chen report they have synthesized a polymer named bacterial poly(3-hydroxybutyrate) (P3HB) that shows early promise as a substitute for petroleum-based plastics. The team’s results recently were published in Nature Communications.

The P3HB biomaterial is typically produced using bacteria, algae and other microorganisms, but its high production costs and limited volumes make more widespread use impractical, according to the CSU researchers.

The method derived at CSU produces P3HB similar in performance to bacterial P3HB, but at a faster rate, which offers the potential for more cost-effective, higher-volume production.

For their research, the CSU team — including research scientist Xiaoyan Tang, the paper’s first author — used succinate as a starting material. Succinate is an ester form of succinic acid and is produced via the fermentation of glucose. The acid appears first on the U.S. Department of Energy’s list of top 12 biomass-derived compounds best positioned to replace petroleum-based chemicals. The researchers also implemented a class of powerful new catalysts they designed, which allowed them to synthesize the P3HB using succinate. A provisional patent has been filed through CSU Ventures for the new technology.

July/August 2018

Royal DSM To Increase Dyneema Capacity

The Netherlands-based Royal DSM has announced plans for an increase in global Dyneema® capacity. The company cites strong demand for both the Dyneema UD uni-directional composite laminate for ballistics and Dyneema fiber as the reason for the expansion.

The company will install new UD technology at its headquarters location in Heerlen, the Netherlands as well as at its plant in Greenville, N.C. The investment also includes upgrades to existing lines to expand both Dyneema UD and fiber capacity. In total, the company will increase Dyneema UD capacity more than 20 percent globally, with the additional capacity expected to come online over the course of 2018 and be complete by the first quarter of 2019.

“Dyneema products are finding use in a broad and ever-increasing range of markets and applications in which lightweight strength is of the essence, for instance best-in-class protective ballistic vests, inserts and helmets,” said DSM Dyneema President Wilfrid Gambade. “These investments will enable us to better accommodate growing customer demand and needs while further extending our global leadership position.”

July/August 2018

U.S. Textiles: High Performance In Every Military Environment

The Infiltrator Jacket available from Seattle-based Outdoor Research® features GORE-TEX® fabric with stretch technology.
The Infiltrator Jacket
available from Seattle-based Outdoor
Research® features
GORE-TEX® fabric
with stretch technology.

TW Special Report

American armed forces are tasked with defending our country in the air, on land and at sea no matter how challenging the environment.

Because of the unique and global nature of this mission, the Department of Defense (DOD) must buy an estimated 8,000 different U.S.-made textile products annually to satisfy its various operational needs. When different sizes are factored into the item mix, there are some 31,000 line items sourced from the textile industry by the military each year.

Fortunately for America, manufacturers like Newark, Delaware-based W.L. Gore & Associates Inc. (Gore) and New Bedford, Massachusetts-based Brittany Global Technologies (Brittany) are up to the job of helping to make textile-based defense products that are the most technically advanced in the world.

Innovations For All Environments, Situations

Famous for its GORE-TEX®-branded consumer products, Gore also is a high-level innovator that manufactures military textiles, including those used in protective gear.

Jason Rodriguez, marketing communications manager, Military Fabrics, W.L. Gore, notes that the environment and a warfighters protection and comfort in that environment are of prime importance to Gore as the company conducts research and development on innovative fabrics for the armed forces.

“Our protective fabrics are designed essentially to help warfighters improve their mission effectiveness by staying alert, staying comfortable, staying dry, and remaining protected no matter what their environment is,” said Rodriguez. “Those are very important elements when developing high-tech fabrics within our business.”

Gore was founded in 1958 by Wilbert “Bill” Lee Gore and his wife Genevieve Walton Gore, initially serving the electronics market. In 1969 when Wilbert’s son Robert “Bob” Gore discovered expanded polytetrafluoroethylene (ePTFE), the company launched GORE-TEX and went on to become a leader in fluoropolymer technologies that apply to many different industries. The first GORE-TEX customer used the fabric in a tent application.

“GORE-TEX is our signature fabric within the Fabrics Division,” Rodriguez said. “It is our legacy product. However, we’re continuing to develop new fabric technologies around that — lighter weight and thinner products within the GORE-TEX portfolio — to continue improving mission effectiveness and assist with lightening the overall load for the warfighter. We are also developing innovations in new areas such as chemical and biological protection; uniforms that leverage ePTFE fiber; and self-extinguishing, flame resistant products.”

Some of Gore’s latest protective technologies for military applications include GORE® CHEMPAK® fabrics— used for chembio uniform applications that feature a stretch technology — and GORE® Katana fabric — a blend of ePTFE, nylon and cotton fibers specifically engineered for hot weather and tropical operations. According to Gore, uniform-specific fabrics optimize air-permeability, dry time and strength-to-weight ratio and can exhibit no melt or drip during flash-fire incidents.

GORE-TEX® PYRAD® is a weatherproof, breathable fabric that was designed to also offer a unique blend of flame resistance (FR), thermal insulation and thermal properties. Gore reports PYRAD® fabrics also are lightweight, fast drying and abrasion resistant. “GORE® PYRAD® is an engineered flame-resistant technology that can be integrated into waterproof and non-waterproof technologies,” Rodriguez said. “The technology has also been leveraged in tent applications.”

“Gore continues to expand our technical fabrics portfolio into areas that are providing enhanced protection against weather, contaminants or flash-fire incidents that the military is faced with,” Rodriguez said. “We focus on delivering this performance in garments, footwear and gloves. It’s a system level approach where Gore can provide a solution that can protect warfighters in the field.”

“In addition to having a rain chamber and various testing labs, Gore recently invested in a state-of-the-art heat and flame lab and comfort chamber,” said Donald C. Vavala, director, Military Government Affairs, Gore. “The heat and flame lab can simulate various test methods traditionally conducted by a third party. The comfort chamber was designed to replicate climates from across the world. Gore keeps investing in assets to ensure we can continue to provide great products now for the warfighter, but also meet the future needs of the warfighter.

“One thing I think helps Gore stand apart from other fabric providers is our comprehensive and robust understanding of our customers’ needs and the end-use application,” Vavala added. “Our commitment to fitness for end use is paramount. Our products undergo rigorous testing both in our facility and in the field to ensure they do what we say they will do first time and every time. We adhere to high standards of quality and product integrity. We want to make sure that our warfighters have an advantage when they are on the battlefield. Their protection is paramount in our minds — their ability to execute the mission and come back from the mission — and anything we can do to help that is hugely important to Gore.”

MilitarytableExpertise Required

Once a high-tech fabric is specified by the military, it must then be fine-tuned with camouflage and other special protective technologies to maximize its effectiveness for warfighters in the field. Brittany Global Technologies specializes in adding these enhancements through dyeing, printing and finishing.

Dyeing and printing are the two most common processing methods to color textiles. While dyeing produces only one color, printing is a more complex process whereby various colored designs are imparted on a fabric surface. Finishing refers to subsequent processes that turn a dyed or printed textile into a more useable product by improving its look, performance and feel.

“The specs are very numerous” said Ken Joblon, president, Brittany Global Technologies. “That’s one of the most challenging aspects of working for the U.S. military — being consistent with the specs as well as matching the colors accurately. They are extremely exacting.”

“The military needs stringent specs because they want the fabric to perform at its very best,” said John Kenyon, COO and vice president, Brittany Global Technologies. “Brittany has state-of-the-art equipment, a lot of technology developed over the years, and the military really looks to us now as someone that can provide the very best fabrics. It’s very proprietary in nature, but we do use special dyes, chemicals and formulations of course,” Kenyon added. “The soldier’s uniform just continues to get better and better. The soldier’s uniform needs to stand up to harsh conditions and needs to fulfill a lot of different functions.”

Brittany maintains a government certified lab with all the necessary testing equipment to be sure it meets the military’s specifications for each product. Every lot is certified with an official government report.

MilitaryBrittany
Ken Joblon has been with Brittany Global Technologies his entire career. His father started the company in 1939 after purchasing a screen printing company for $300.

Brittany, founded in 1939, is a second-generation family business with a long history in textile printing and dyeing. In the early 2000s, the company — feeling pressure from low-cost imports — began investigating new markets to strengthen its business. The company’s willingness to innovate and diversify rather than stand still, led them to the military business.

“I feel gratified to play a part in equipping our military,” Joblon said. “I know our military has the best equipment available. We are all proud of what we do here, and it’s a fast-moving business. We have to be very nimble as things happen fast, and we must respond very quickly. In order to respond, many pieces must be in place, a few of which include having raw materials on hand, to having the right machinery, and having trained people to take care of whatever needs the government may have. That’s our culture.”

Editor’s Note: This article appears in Textile World courtesy of the National Council of Textile Organizations (NCTO) as part of the “American Textiles: We Make Amazing™” campaign. NCTO is a trade association representing U.S. textile manufacturing. Please visit ncto.org to learn more about NCTO, the industry and the campaign.

July/August 2018

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