Smart Textile Using Embroidered Cu-Zn-Coated Aramid Threads for ECG Monitoring

This study presents the design and evaluation of a smart textile ECG monitoring garment developed for continuous, comfortable, and reusable cardiac health tracking. The system incorporates Cu-Zn-coated aramid conductive threads embroidered onto a polyester-cotton knitted fabric to form dry textile electrodes, which are connected to a wireless ECG sensing unit based on the AD8232 analog front end and an ESP32 microcontroller for real-time signal transmission. A lightweight polyethylene sheet was integrated beneath the electrodes and circuitry to provide water and sweat resistance without significantly compromising comfort. Characterization tests showed low electrode resistance (10–20 Ω), washability up to 10 cycles, and good mechanical durability. The device captured clear PQRST waveforms at a 250 Hz sampling rate with a signal-to-noise ratio of 15–25 dB, achieving 90–95% signal quality compared to gel electrodes under resting conditions. Air permeability decreased slightly with embroidery and more significantly in polyethylene-backed regions, though the garment remained wearable and breathable. User testing confirmed accurate heart rate detection and high comfort, with ECG signals stabilizing within 30 seconds of wear. These findings demonstrate that the smart textile ECG garment is a viable, comfortable, and reusable alternative to conventional systems, suitable for long-term and home-based cardiac monitoring applications.