Abstract

The integration of intelligent sensor systems into textiles opens up new possibilities across various industries, from healthcare and sports to protective clothing and entertainment. Smart textiles, equipped with conductive tracks and embedded sensors, enable continuous monitoring of physiological parameters and interaction with the environment. A key method for manufacturing such textiles is laser-based metallization, which allows precise and selective deposition of conductive traces onto a variety of synthetic fabrics. Copper is one of the preferred materials for metallization due to its excellent conductivity. Through selective laser metallization, these traces can be flexibly embedded into the textile structure without compromising its mechanical properties. This technology enables the creation of thin, durable conductive layers, which can be combined with various sensors. The resulting textiles can be designed to be flexible, lightweight, and wearable, making them ideal for applications in health monitoring, sports science, and industrial protective clothing. Despite the vast potential of laser- based metallization, several challenges remain, including ensuring the durability and washability of metallized surfaces, long-term power supply for integrated sensors, and data security. This publication explores the current advancements and challenges in selective laser metallization of synthetic textiles (Figure 1).

Figure 1:Design study of a smart textile with selective copper conductive tracks and an integrated sensor.

Keywords:Smart textile; Laser-based selective activation; Electrical conductance; Sensor integration