Exploring Machine-Sewing as a Fabrication Method to Create Fabric-Based Circuits and Breadboards for E-textile Prototyping

Abstract

This thesis explores machine-sewing as a primary fabrication method for developing e-textile circuits and fabric-based breadboards to support e-textile prototyping. While existing e-textile kits mainly rely on hand-stitching, which limits scalability and complexity, this work investigates how domestic sewing machines can be used to create robust, interactive textiles more efficiently. Using a Research through Design methodology, we contribute a collection of 11 machine-sewing techniques for creating conductive paths, terminating connections, and securing electronic components. We developed four techniques for fabricating machine-sewn sensors, which we demonstrate through four real-world applications of machine-sewn interactive garments. Additionally, we explore the iterative design of a series of fabric-based breadboards, termed “FabricBoard”, designed to align with the material needs of e-textiles. We developed three main FabricBoard designs, resulting from 13 iterations, to broaden the design space of fabric-based breadboards across four axes: native materiality, connection stability, visual clarity, and design compatibility. A user study with 18 participants evaluated the interaction and user experience of fabric-based breadboards, revealing themes related to materiality, visual clarity, tool complexity, and user engagement. The outcomes of this thesis contribute practical methods, design recommendations, and novel prototyping tools that broaden the accessibility of e-textile design.