Electrical Fibers for Intelligent Textiles: From Conductivity–Flexibility Trade-offs to Scalable Systems

Abstract

Intelligent textiles capable of sensing, communication, and energy interaction require electrical fibers (elecfibers, ECFs) to function as system-level building units rather than passive conductors. Beyond charge transport, ECFs must integrate electrical performance with mechanical compliance, interfacial stability, and device functionality within deformable textile architectures. This transition is constrained by four coupled challenges: balancing conductivity and flexibility; managing degradation from multifunctional interfaces; bridging the gap between fiber-level properties and textile-scale behavior governed by contact resistance and dynamic deformation; and translating laboratory performance into scalable manufacturing and long-term reliability under washing, sweating, abrasion, and environmental exposure. This review addresses these challenges through a cross-scale, problem-oriented framework. We examine conduction mechanisms and fiber architectures that govern the conductivity–flexibility trade-off, followed by multifunctional integration in thermal, electromagnetic, sensing, communication, and energy systems, with an emphasis on interfacial reliability. Cross-scale electrical behavior is analyzed from local pathways to textile networks and system-level performance, while scalable fabrication and reliability evaluation are identified as prerequisites for deployment. By redefining ECFs as system-level components, this review establishes design principles centered on conductive continuity, interfacial stability, and cross-scale integration, enabling intelligent textiles with reliable, durable, and manufacturable performance.

Keywords

Electrical fibers / Intelligent textiles / Functionalization / Flexible electronics / Scalable systems

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Funding

National Natural Science Foundation of China(62404113)

Rights & permissions

Donghua University, Shanghai, China