This article presents a comprehensive technical analysis of CPLD vs FPGA, focusing on their architectural distinctions, performance metrics, design flows, and implementation methodologies. 

CPLD vs FPGA: A Comprehensive Technical Analysis and Implementation Guide

<h2 id="isPasted">Programmable Logic Controller (PLC)</h2><p>A PLC is designed to control part or all of a manufacturing process and is simple to use and set up, even for entry-level programmers. A PLC can diagnose faults quickly, and its modular design allows for tailor-made systems to suit every application. A PLC is a highly reliable industrial computer constructed from high-grade, durable materials that can withstand a range of environmental pressures. Its real-time response to changing conditions means operations continue uninterrupted, even when a fault is being resolved.</p><h2>Human Machine Interface (HMI)</h2><p>An HMI is what enables human interaction with the machines that are doing the work, and usually consists of a panel interface that may have keypads, displays and USB connections. While human beings control and operate the machine via the HMI, the machine closely monitors production and simultaneously feeds back information to the operator. This allows quicker and more accurate decision-making and a rapid response to constantly changing production demands.</p><h2>Distributed Control System (DCS)</h2><p>A Distributed Control System is one where a network of autonomous machine controllers is centrally governed by a supervisory operator. Various nodes and control processors are placed at strategic points throughout the manufacturing system, where they can assist in batch-orientated or continuous processes. This means that any problems in the system are localised and only affect that part of the manufacturing process directly controlled by the node, thus reducing overall production downtime.</p><h2>Supervisory Control and Data Acquisition (SCADA)</h2><p>SCADA is a more complex automation concept, referring to a control system architecture which provides an advanced level of supervisory plant management. This architecture comprises a whole network of computers, in one or more locations, combined with a user interface and high speed data communications which allow a distributed network to be accessed remotely.</p><h2>Artificial Neural Network (ANN)</h2><p>An ANN is the basis of Artificial Intelligence and is effectively a computer model based on a biological brain. The brain's neural structure comprises a network of interconnected sensors and synapses, which receive and transmit information to a biological creature and control its responses to received sensory data. The big advantage of a neural network is that it learns by processing and adapting both internal and external information, and an ANN does this in the same way as a biological one. ANNs process data sets and learn from the information there so that they can respond to problems and produce solutions from their own computational capacity.</p>

Automation concepts cover a range of increasingly complex machine initiatives that enhance all areas of 21st century life, and are especially useful for streamlining commercial and production processes.

Five Key Concepts in Automation

<p><strong>How can virtual reality (VR) be experienced haptically, i.e., through the sense of touch? This is one of the fundamental questions that modern VR research is investigating. Computer scientist André Zenner, who is based in Saarbrücken, Germany, has come a significant step closer to answering this question in his doctoral thesis – by inventing new devices and developing software-based techniques inspired by human perception. He has now been awarded the prestigious "Best Dissertation Award" at the world's leading VR conference.</strong></p><p id="isPasted">The award-winning work is about how physical props (technical term: "proxies") can be used to make objects in virtual environments tangible. "Of course, you can't have a proxy for every virtual object, then the approach wouldn't be scalable. In my dissertation, I, therefore, thought about what devices could look like that could be used to simulate the physical properties of several different virtual objects as effectively as possible," explains André Zenner, who completed his doctorate at the Saarbrücken Graduate School of Computer Science at Saarland University and is now conducting research at Saarland University and the German Research Center for Artificial Intelligence.</p><p>This resulted in the prototypes for two special VR controllers, "Shifty" and "Drag:on." VR controllers are devices that can be held in the user’s hand to control or manipulate objects in virtual reality using tracking technology.</p><p><a target="_blank"></a></p><header><h2>Shifty</h2></header><p>"Shifty" is a tubular controller in which a movable weight is installed. The weight can be moved along the lengthwise axis by a motor, changing the center of gravity and inertia of the rod. "In combination with corresponding visualizations in virtual reality, Shifty can be used to create the illusion that a virtual object is getting longer or heavier," explains André Zenner. In experiments, he was able to prove that objects are perceived as lighter or smaller when the weight is close to the user's hand and that, coupled with the corresponding visual input; they are perceived as longer and heavier the further the weight in the rod moves away from the user. "This is mainly due to changes in the inertia of the controller, as the overall weight does not change," explains André Zenner. The research and development department of gaming giant Sony is already experimenting with this concept and cites André Zenner's work in the development of new VR controllers.</p><p><a target="_blank"></a></p><header><h2>Drag:on</h2></header><p>The second controller, "Drag:on," consists of two flamenco fans that can be unfolded using servomotors, thus increasing the air resistance of the controller. This means that the further the fans are unfolded, the more force the user has to exert to move the controller through the air. "Coupled with the right visual stimuli, Drag:on can be used to create the impression that the user is holding a small shovel or a large paddle, for example, or that they are pushing a heavy trolley or are twisting a knob that is difficult to turn," explains André Zenner. Both controllers are basic research and so-called "proof of concepts." This means that the prototypes can be used to show in user experiments that different controller states can improve the perception of different VR objects. Still, specific products using this technology are not yet available on the market.</p><p><a target="_blank"></a></p><header><h2>Similarity and colocation problem</h2></header><p>With the controllers, the Saarbrücken-based computer scientist first addressed the so-called ‘similarity problem.’ The aim here is to ensure that virtual and real objects feel as similar as possible. In the second part of his work, he dealt with the so-called ‘colocation problem,’ i.e., the question of how the proxy can be spatially located in real life where the user sees it in virtual reality. This is particularly challenging as the controllers act as proxies for different virtual objects. Consequently, the user must be given the illusion that they are reaching for various objects, although in reality, they will always grasp the same proxy.</p><p>To achieve this, the researcher made use of the already established method of "hand redirection." As the name suggests, this involves redirecting the movement of the hand in virtual reality so that the user thinks they are reaching to the left, for example, even though they are actually stretching their hand forward. "We conducted experiments to investigate the point at which users realize that their hand has been redirected. Our results showed that this point was reached quickly, so we thought about how we could better conceal the hand redirection," says André Zenner. The solution: he tricked the brain by only redirecting the hand when the brain was blind to visual changes - namely during blinking. Together with a student under his supervision, he developed the appropriate software and used the eye trackers built into many VR headsets. In control studies, the team was then able to show that their new controllers, in combination with hand redirection algorithms, led to more convincing VR perceptions than previously possible.</p><p>This research achievement has now been recognized internationally. The work entitled "Advancing Proxy-Based Haptic Feedback in Virtual Reality" was awarded the "IEEE VGTC Virtual Reality Best Dissertation Award" in mid-March at the "IEEE Conference on Virtual Reality and 3D User Interfaces", which took place this year in Orlando, Florida. According to the IEEE, the award is presented each year to the author of the most outstanding dissertation defended in the previous two calendar years in the research fields of virtual and augmented reality. A total of 16 dissertations were submitted to the 2024 edition of the conference and reviewed by an international committee of experts. The thesis was supervised by Prof. Dr. Antonio Krüger, CEO of the German Research Center for Artificial Intelligence and Head of the Ubiquitous Media Lab at Saarland University.</p><hr><p><strong>Original Publication:&nbsp;</strong>Zenner, A. (2022). Advancing Proxy-Based Haptic Feedback in Virtual Reality. Universität des Saarlandes. <a href="https://dx.doi.org/10.22028/D291-37879" target="_blank" rel="noreferrer">doi:10.22028/D291-37879</a></p>

How can virtual reality (VR) be experienced haptically, i.e., through the sense of touch? This is one of the fundamental questions that modern VR research is investigating.

Tricking the brain: New dimensions of haptics in virtual reality

<h2 dir="ltr" id="isPasted">Introduction - Tracing Past and Present Trends</h2><p dir="ltr">The way we interact with machines has undergone a remarkable transformation. Mechanical buttons and levers once defined our control over devices. Then, touchscreens revolutionised the user experience, providing a direct and intuitive way of issuing commands. Today, we stand on the cusp of another major shift—the rise of touchless human-machine interfaces (HMIs). A human-machine interface is the platform through which humans interact with machines, systems, or devices.<sup>[1]</sup> HMIs translate complex data into a user-friendly format.</p><p dir="ltr">Why embrace this change? Touchless HMIs offer compelling advantages. They empower individuals with disabilities to interact with technology independently, opening doors to communication and control that were once inaccessible. Furthermore, they promote hygiene in public environments like hospitals and kiosks, minimising the spread of germs through shared touch surfaces.<sup>[2]</sup> Perhaps most importantly, these interfaces often provide a more natural and intuitive user experience – we instinctively communicate through speech and gestures, and these interfaces reflect those inherent patterns.<br><br>In this article, we will examine how touchless HMIs enhance the user experience, explore their applications in various sectors, and discuss their potential for the future of communication between humans and machines.</p><h2 dir="ltr">Navigating the Shift from Traditional Interfaces</h2><p dir="ltr">Human-machine interfaces began with the simple yet enduring pushbutton and dial. For decades, these physical controls were the primary means of directing machines. While reliable, they were often cumbersome and inefficient, especially when dealing with complex systems.<sup>[1]</sup> A factory floor, for instance, might require a vast array of buttons and dials to manage its machinery, adding complexity to the operator's task.&nbsp;</p><p dir="ltr">The advent of Programmable Logic Controllers (PLCs) brought about a significant shift. PLCs are essentially industrial computers that automate tasks based on programmed logic.<sup>[3]</sup> While revolutionising automation, direct interaction with PLCs typically involved specialised interfaces, often text-based or requiring specific code knowledge. This created a barrier between operators and the machinery they supervised, slowing down configuration and troubleshooting. Compared to the intuitive operation of pushbuttons and dials, PLCs demanded a steeper learning curve for operators.</p><p dir="ltr">Touch panels provided a significant leap forward in HMI design. These intuitive interfaces replaced many physical controls with digital ones, offering greater flexibility and a more streamlined user experience. Operators could easily switch between control screens, monitor multiple processes at once, and access detailed diagnostics with the touch of a finger. However, touchscreens still carry limitations. They rely on direct physical contact, a hygiene concern in sensitive environments.<sup>[4]</sup> They also demand a user's proximity to the device.</p><p dir="ltr">As touch panels matured, voice control emerged as the next frontier in HMI development. Voice-enabled interfaces allow users to issue commands and control devices hands-free. This Touchless HMI technology is transformative in various industries. A surgeon, for instance, could access patient records or adjust medical equipment during a procedure without breaking sterility. Factory workers might remotely control machinery using voice commands, enhancing productivity and safety. Moreover, voice control opens new avenues for remote monitoring and managing industrial processes. Engineers can troubleshoot issues, receive alerts, and make adjustments from anywhere, leading to faster response times and less reliance on on-site personnel.&nbsp;</p><h2 dir="ltr">How Touchless HMI Works and Emerging Trends</h2><p dir="ltr">Touchless HMIs seem like magic, but they rely on sophisticated technologies to bridge the gap between humans and machines. Voice control systems use natural language processing (NLP) to understand and respond to our spoken words.<sup>[5]</sup> Specialised devices track and interpret hand gestures, translating motions into commands. Meanwhile, eye-tracking systems monitor our gaze, allowing us to select items, navigate menus, or even scroll through documents simply by shifting our focus. These are just the beginnings of touchless control, and the potential for new and innovative interaction methods is as vast as our imaginations.</p><h3 dir="ltr">Smart Homes: Control lighting, temperature, appliances with voice or gestures</h3><p dir="ltr">These human-machine interfaces transform the way we interact with our homes. We speak a&nbsp;<iframe id="6630fcb690a5a9207458ee75" width="250" class="specs-iframe" height="440" src="https://wevolver.com/iframe/specs/microchip-technology-rnwf02-early-access-development-kit?iframe=true" frameborder="0" scrolling="no" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe> simple command to adjust the lights, change the temperature, or play our favourite music. We wave our hand to pause the smart TV or draw a gesture in the air to close our blinds. Wall-mounted interfaces, often found in high-end systems, provide comprehensive home control with visual feedback and easily complement voice and gesture commands.&nbsp;</p><p dir="ltr">Smart home technology goes beyond individual commands. Location tracking can trigger actions automatically, like turning lights on when you arrive home or locking doors when you leave. Create personalised, pre-programmed sequences - like a "Goodnight" scene that automatically dims lights, lowers the thermostat, and arms the security system, all activated by a simple voice request or a quick gesture. Such human-machine interfaces bring convenience, flexibility, and even a touch of magic to our living spaces.&nbsp;</p><h3 dir="ltr">Cars: HMIs that minimise distractions while driving (voice, gesture-based)</h3><p dir="ltr">These interfaces promise to make our interactions with vehicles safer and more intuitive. Head-up displays (HUDs) exemplify this by directly projecting critical driving information (speed, navigation cues) onto the windshield.<sup>[6]</sup> This allows drivers to focus on the road ahead, minimising distractions inherent in glancing down at a traditional dashboard. Additionally, voice control and gesture recognition systems enable drivers to adjust climate settings and music or answer calls without needing to take their hands off the wheel.</p><p><br></p><p dir="ltr"><span class="fr-img-caption fr-fic fr-dii" style="width: 781px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNzE1NzcwMjc4NzMyLTE3MTU3NzAyNzg3MzIucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" width="624" height="416" class="fr-fic fr-dii"><span class="fr-inner" spellcheck="false">A heads-up navigation display of a car showing directions, speed, and time. Image credit:&nbsp;<a href="http://www.freepik.com/" target="_blank" id="isPasted">Freepik</a> -&nbsp;<a href="https://www.freepik.com/author/rawpixel-com" target="_blank">rawpixel.com</a></span></span></span></p><p dir="ltr" id="isPasted">Augmented reality (AR) takes the concept of HUDs even further. In AR-powered HUDs, a transparent surface called a combiner acts as a display. Information is overlaid directly onto the driver's field of view, merging with the real world. Imagine navigational arrows visually guiding you through turns or hazard warnings highlighting obstacles on the road. AR systems have vast potential for improving drivers' situational awareness and decision-making. The field of view (FOV) of an AR display is crucial, as it defines the size of the area where information can be projected.</p><h3 dir="ltr">Healthcare: Assistive HMIs for individuals with limited mobility</h3><p dir="ltr">Touchless HMIs offer incredible potential for those with disabilities that affect their motor function. Voice and gesture-based interfaces can empower individuals with limited mobility to operate once inaccessible devices. For instance, a patient with paralysis might control an intelligent bed to adjust its position, call for assistance through a voice-powered home system, or even operate a computer using eye-tracking technology.</p><p dir="ltr">HMIs on some kidney dialysis machines display critical patient information, such as blood pressure and flow rates, while allowing technicians to adjust treatment parameters accurately. MRI scanners rely on sophisticated HMIs that guide the operator through the scanning process, enabling image selection and controlling imaging parameters.<sup>[2]</sup> Often cardiac defibrillators feature clear, intuitive HMIs that guide doctors through life-saving procedures, provide step-by-step instructions, and minimise the potential for errors in highly stressful emergencies</p><p dir="ltr">Beyond day-to-day activities, touchless HMIs open doors to communication, entertainment, and self-expression. Individuals with speech impairments could use text-to-speech systems controlled by gestures or eye movements, allowing them to interact with others. In both therapeutic and home settings, interfaces that respond to even minimal gestures can facilitate access to music, art creation tools, and games, promoting independence and improving quality of life.&nbsp;</p><h2 dir="ltr">Applications of HMIs in Industrial Automation</h2><p dir="ltr">HMIs integrate with key control systems such as Supervisory Control and Data Acquisition (SCADA), Enterprise Resource Planning (ERP), and Manufacturing Execution Systems (MES). This integration provides a centralised view and control point for complex manufacturing processes. Operators enjoy a visual representation of machinery status, production data, and resource management, empowering them to make informed decisions in real-time.&nbsp;<iframe id="65cdfb042e974dd551480b6b" width="250" class="specs-iframe" height="440" src="https://wevolver.com/iframe/specs/silicon-labs-xg28-pk6024a-868-915mhz-ble-14dbm-pro-kit?iframe=true" frameborder="0" scrolling="no" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></p><p dir="ltr">By making process visualisation and control easy, HMIs contribute significantly to enhanced efficiency on the factory floor. Operators can quickly identify bottlenecks, fine-tune production parameters, and reduce downtime through prompt troubleshooting. The clear presentation of key performance indicators (KPIs) provided by modern interfaces drives data-backed optimisation at every stage of the manufacturing process.&nbsp;</p><p dir="ltr">HMIs also enable remote monitoring and management. Engineers and technicians can access real-time data on production lines from anywhere, receive alerts on critical events, and take preventive measures to mitigate potential issues. This remote capability reduces the need for on-site personnel, especially in hazardous or remote locations, boosting productivity and optimising resource allocation. With secure, cloud-based interfaces, manufacturers can monitor and control operations across multiple facilities, facilitating centralised decision-making and accelerating response times.</p><h2 dir="ltr">The Benefits and Challenges</h2><p dir="ltr">Touchless HMIs offer significant advantages. They transcend limitations for individuals with disabilities. Voice-controlled interfaces bridge communication gaps, while gesture or eye-tracking systems can facilitate control over personal devices and augmentative technologies. Beyond accessibility, they promote improved hygiene — a vital consideration in high-traffic public areas. With such technology, self-service kiosks at airports or restaurants can be operated without direct touch, minimising the spread of germs from many users.</p><p dir="ltr">However, challenges exist. Accuracy remains a concern, especially for voice control in noisy environments or for users with non-standard speech patterns. These HMIs collect vast amounts of data — voices, gestures, and eye movements — raising serious privacy considerations. Ensuring robust data protection and transparency on how information is used will be crucial for widespread adoption. Furthermore, for these interfaces to be truly effective, they must be compatible across various devices and platforms, as a lack of standardisation can be a barrier to integration.</p><h2 dir="ltr">Designing Interfaces for the Future</h2><p dir="ltr">The future of HMI design goes beyond purely functional interfaces. Medical devices, in particular, demand HMIs that are intuitive, reliable, visually appealing, and even calming. &nbsp;Smooth surfaces and clean lines can promote a sense of hygiene and sterility. At the same time, strategic use of colour and illumination in buttons and switches can quickly convey status or guide user action. Even in critical situations, well-designed HMIs should strive to reduce stress and facilitate quick, confident interactions.</p><p dir="ltr">While touchless technologies are exciting, tactile feedback remains indispensable in high-stakes environments like healthcare. The satisfying click of an illuminated pushbutton provides instant confirmation of an action. Emergency stop buttons must be instantly recognisable and easily actuated, providing fail-safe peace of mind during urgent situations.</p><p dir="ltr">Future HMIs must balance innovation and reliability, integrating cutting-edge technologies while preserving the essential elements that promote safety and an exceptional user experience. While still nascent, brain-computer interfaces (BCIs) are also on the horizon. Users will control devices with subtle thoughts, blurring the lines between humans and machines in unprecedented ways.<sup>[7]</sup></p><h3 dir="ltr">References</h3><ol><li dir="ltr"><p dir="ltr">Papcun P, Kajáti E, Koziorek J. Human-machine interface in concept of industry 4.0. 2018 World Symposium on Digital Intelligence for Systems and Machines (DISA) 2018 Aug 23 (pp. 289-296). IEEE.</p></li><li dir="ltr"><p dir="ltr">Singh HP, Kumar P. Developments in the human-machine interface technologies and their applications: a review. Journal of medical engineering &amp; technology. 2021 Oct 3;45(7):552-73.</p></li><li dir="ltr"><p dir="ltr">Alphonsus ER, Abdullah MO. A review of the applications of programmable logic controllers (PLCs). Renewable and Sustainable Energy Reviews. 2016 Jul 1;60:1185-205.</p></li><li dir="ltr"><p dir="ltr">Bhardwaj N, Khatri M, Bhardwaj SK, Sonne C, Deep A, Kim KH. A review on mobile phones as bacterial reservoirs in healthcare environments and potential device decontamination approaches. Environmental research. 2020 Jul 1;186:109569.</p></li><li dir="ltr"><p dir="ltr">Rani PJ, Bakthakumar J, Kumaar BP, Kumaar UP, Kumar S. Voice controlled home automation system using natural language processing (NLP) and internet of things (IoT). In2017 Third International Conference on Science Technology Engineering &amp; Management (ICONSTEM) 2017 Mar 23 (pp. 368-373). IEEE.</p></li><li dir="ltr"><p dir="ltr">Ward NJ, Parkes A. Head-up displays and their automotive application: An overview of human factors issues affecting safety. Accident Analysis &amp; Prevention. 1994 Dec 1;26(6):703-17.</p></li><li dir="ltr"><p dir="ltr">Zander TO, Gaertner M, Kothe C, Vilimek R. Combining eye gaze input with a brain-computer interface for touchless human-computer interaction. Intl. Journal of Human-Computer Interaction. 2010 Dec 30;27(1):38-51.</p></li></ol>

Discover the transformative shift in human-machine interaction as touchless technologies redefine how we interact with machines.

Human machine interfaces enhance user experience through touchless technology

<p id="isPasted">We’ve heard the saying that modern cars are like computers on wheels. Well, vehicles are also like smartphones on wheels. Familiar and favorite apps from your phone are now available natively inside your ride. You can listen to streaming music, play a movie, map a route to the nearest ATM, and soon even order dinner or your favorite beverage on the way home or to work.</p><p>We’re in the age of <a href="https://www.synopsys.com/blogs/chip-design/software-defined-vehicles-changes-auto-design.html" target="_blank">software-defined vehicles</a>, where automotive functions and features are driven more by software than by mechanical components. Over-the-air (OTA) updates allow carmakers to correct software bugs, deliver new capabilities (including apps!), and assess the vehicle’s operation. This way of constantly modifying the vehicle also presents opportunities for collaboration with third parties for new offerings—and new revenue streams.</p><p>However, as with any electronic system, vehicles can be ripe for cyberattack if not properly protected. OTA updates, especially when they involve third parties, represent a potential area of vulnerability. In this article, I’ll highlight key security considerations of OTA updates and in-vehicle apps and the measures that should be taken to keep cars safe and secure.</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk3NjMxMDI3NDAzLW9wdGljYWwtc2NhdHRlcmluZy1hdXRvbW90aXZlLndlYnAiLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 300px;" class="fr-fic fr-dib"></p><section id="isPasted"><h2>Automotive Software Is Driving Vehicle Evolution</h2><p>OTA updates are delivered over a cellular network, Wi-Fi, or other radio frequency- (RF-) based methods that provide software updates. This grouping of technologies offers a fast and convenient way for vehicle manufacturers to resolve issues and future-proof their cars, all without requiring car owners to visit the dealer. There isn’t currently a standardized way in the automotive industry to verify software updates. As such, it’s possible for an OEM to have multiple ways to confirm software updates for some of its components or to rely on a complex supply chain for the delivery of these updates. But this should change as the software-driven features become further ingrained in the industry.</p><p>In the U.S., the National Highway Traffic Safety Administration (NHTSA) offers security guidance through its <a href="https://www.nhtsa.gov/sites/nhtsa.gov/files/2022-09/cybersecurity-best-practices-safety-modern-vehicles-2022-tag.pdf" target="_blank" data-lf-fd-inspected-kn9eq4roawkarlvp="true">Cybersecurity Best Practices for the Safety of Modern Vehicles</a> report. The report outlines steps for vehicle manufacturers to take to mitigate the risk of cyberattacks. NHTSA isn’t alone in this endeavor. The EU has issued<a href="https://unece.org/transport/documents/2021/03/standards/un-regulation-no-155-cyber-security-and-cyber-security" target="_blank">&nbsp;UN Regulation No. 155,</a> which has clear requirements that require OTA capabilities to update vehicles in order to sell in that market.</p><p>Efforts generally begin with a risk assessment, outlining components in a vehicle that any application would interact with. But then, there are a lot of questions about risk and responsibilities. As an example, let’s consider a self-parking application that’s activated by a smartphone. The vehicle in question already has autonomous driving capabilities. However, to enable self-parking, the driver needs to install an app that is tied to a parking garage company and must be allowed to communicate with the vehicle. For this application to work, the carmaker needs to provide location and other vehicular data to the app so that the car can navigate safely through the garage to an available parking spot once prompted by the driver. Is the OEM responsible for monitoring and managing the app’s security and capability, or is it the supplier's responsibility to ensure that the app contains nothing malicious or compromised? Many of these questions will be resolved by legal departments, but proper cybersecurity hygiene is the primary focus for minimizing these types of events.</p><p>In-vehicle apps such as the self-parking example represent a new revenue stream, and the opportunities are wide open for a host of new and exciting capabilities. Imagine having a car that knows your favorite morning coffee order—once you step inside for your commute, the car has already placed the order, handled the payment, and is navigating the fastest route to the café for order pickup. Or, what if different in-vehicle apps could interact with one another? Your car senses—thanks to an app plus a tracking tag on the bag—that you have clothes in the trunk for the dry cleaner. The dry-cleaning app communicates with the café app, directing the car on the most efficient route to drop off the dry cleaning and pick up your coffee.</p><p>The apps themselves must have built-in protections against malicious attacks. When they’re ready to be updated, the OTA updates must flow securely from server to vehicle, with little risk that the data will be intercepted and compromised.</p><p>These days, carmakers and app developers are collaborating closely, though a primary focus is getting new capabilities to market. At the consumer level, it may be several years before we start seeing these example scenarios come to fruition. Enterprise-level innovations may come sooner. <a href="https://www.thewrap.com/pizza-hut-new-driverless-delivery-vehicle-scares-black-mirror-fans/" target="_blank">Pizza Hut, for example,</a> is exploring a driverless concept vehicle equipped with a pizza oven, a move that could transform how food is ordered, prepared, and delivered.</p><p>Regardless of when these new offerings are available, the time is ripe to start addressing the security considerations.&nbsp;</p></section><section><h2>Keeping Connected Vehicles Safe and Secure, Inside and Out</h2><p>The risk assessment is a solid starting point that requires the right people for the task. Also important is assigning areas of responsibility, as well as accounting for the steps and actions needed to mitigate security risks. Carmakers would be wise not to rely on third-party app developers to understand the security requirements of their vehicles. These requirements will vary widely across vehicle types and manufacturers. A secure set of application programming interfaces (APIs) for the app developers is a good safeguard and opens an opportunity to monitor and limit access. This way, if anything inappropriate happens with the app, the vehicle would know how to react and potentially protect itself. Another important element is establishing a protective layer for the vehicle subsystems, enabling a safe, secure way for third parties to interact with the vehicle to deliver value-added services.</p><p>Key elements of an effective OTA software update security program include having a robust public key infrastructure (PKI), well-defined software verification and validation practices, and effective vehicle software deployment, storage, and activation. The automotive industry can also take some lessons from the mobile device industry – smartphone makers, for example, must apply robust security measures to ensure that their devices, the apps installed on them, and the data accessible by these apps remain safe and secure. Carmakers must do the same across all their product lines.</p><p>A variety of security and monitoring technologies is available to support carmakers. For the vehicles themselves, automotive engineers can employ <a href="https://www.synopsys.com/automotive.html" target="_blank">electronic digital twin solutions</a>, which provide virtual environments to test silicon solutions before they are deployed. As we see more consolidation of in-vehicle compute platforms, traditional methods to test silicon for security become impractical given all the touch points in these complex environments. Electronic digital twins provide an answer. <a href="https://www.synopsys.com/solutions/silicon-lifecycle-management.html" target="_blank">Silicon lifecycle management (SLM)</a> sensors and monitors can track electronic component behavior over time, from in-design stages to the field. With SLM, automotive engineers have a way to evaluate how devices are performing under their workloads over the long lifespan of vehicles.</p><p>On the software side, <a href="https://www.synopsys.com/software-integrity/security-testing/static-analysis-sast.html" target="_blank">static application security testing</a>, <a href="https://www.synopsys.com/software-integrity/security-testing/fuzz-testing.html" target="_blank">fuzz testing</a> to uncover security weaknesses, and <a href="https://www.synopsys.com/software-integrity/code-dx.html" target="_blank">application vulnerability correlation</a> to diagnose and manage software risk are among the solutions available to safeguard in-vehicle apps and OTA updates.</p><p>OTA updates are an efficient and cost-effective way for carmakers to future-proof vehicles, provide updates, or keep cars out of the dealerships for recall fixes. As with any electronic component or software solution, these updates as well as the in-vehicle apps that enrich the driver experience can all be vulnerable to cyberattacks. Conducting a thorough risk assessment, assigning areas of security responsibility, and deploying both hardware and software security solutions can help keep vehicles safe and sound for the long haul.</p><p>Read more about&nbsp;<a href="https://wevlv.co/synopsys3" target="_blank" rel="noopener noreferrer">Key Considerations for Securing In-Vehicle Apps</a>.<br><br><strong><em>Read more about Synopsys in previously published articles:</em></strong></p><p id="isPasted"><a href="https://www.wevolver.com/article/designing-energy-efficient-ai-accelerators-for-data-centers-and-the-intelligent-edge" target="_blank" rel="noopener noreferrer">Designing Energy-Efficient AI Accelerators for Data Centers and the Intelligent Edge</a></p><p id="isPasted"><a href="https://www.wevolver.com/article/why-ai-requires-a-new-chip-architecture" target="_blank" rel="noopener noreferrer">Why AI Requires a New Chip Architecture</a></p></section>

Balancing Innovation with Safety in the Age of Smart Mobility



Key Considerations for Securing In-Vehicle Apps

<p id="isPasted">Thibaut Soulestin, PhD ; Lead Application Engineer at Henkel Printed Electronics; <a target="_blank" rel="noopener noreferrer" data-fr-linked="true" href="mailto:thibaut.soulestin@henkel.com">thibaut.soulestin@henkel.com</a></p><p>Henkel Adhesive Technologies has developed a large material portfolio of conductive inks and coatings suitable for printed electronics technology. Our portfolio offers material solutions ideal for various smart surface technologies, including self-regulating foil heaters. Self- regulating foil heaters are enabled by Henkel’s Positive Temperature Coefficient (PTC) inks in combination with silver and dielectric inks. Understanding the origin of the PTC effect, typical characterizations, and basic design rules enable our customers to reveal the full potential of this technology.</p><h3>1 &nbsp; Introduction to Henkel Positive Temperature Coefficient (PTC) carbon inks</h3><p>Different types of conductive polymer composites (CPC) exhibit positive temperature coefficient (PTC) properties. They have been extensively studied and some are commercially available. A vast majority is obtained by compounding a polymer binder with conductive fillers, mostly carbon-based.</p><p>The increase in resistance of the conductive networks during heating is caused by the thermal expansion of the polymer and the change in the distance between the conductive fillers. The PTC effect usually occurs during the phase transition of the polymer matrix, the glass transition, or the melting. After the maximum PTC effect, if the temperature keeps rising, a negative temperature coefficient (NTC) effect can be observed due to the re-aggregation of the conductive particles.</p><p>Henkel carbon PTC inks are like other screen-printable carbon inks and are based on three main components:</p><p>&nbsp; &nbsp; &nbsp; &nbsp; (i) &nbsp;carbon particles for the electrical conductivity,</p><p>&nbsp; &nbsp; &nbsp; &nbsp; (ii) &nbsp;a polymer binder for the mechanical properties and adhesion to the substrate, and</p><p>&nbsp; &nbsp; &nbsp; &nbsp; (iii) &nbsp;a solvent.</p><p>The dry ink layer is then obtained after drying and solvent evaporation.</p><p>Henkel developed a specific and patented technology using micronized wax particles to introduce the PTC effect. A fine wax powder is added as a fourth main component to the ink. The resistance will increase exponentially near the wax melting point, resulting in a high PTC ratio and a well-controlled self-regulation temperature. By finely controlling the melting point and the size of the wax particles, and thus the particles’ volume expansion, the PTC effect can be finely tuned to match customer requirements.</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk1MjAxOTg1OTI0LVNjcmVlbnNob3QgMjAyMy0wOS0yMCAwOTI1NTIucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 544px;" class="fr-fic fr-dib"></p><p>Figure 1. Schematic graph representing the exponential increase of resistance of Henkel positive temperature coefficient (PTC) ink. At a defined temperature, the micronized wax particles (spherical white), nicely dispersed between the carbon particles (black ovals), increase in volume, pulling apart the conductive carbon particles, leading to the resistance increase.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 736px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1699454978001-B-and-B-2024%28blog%29.jpg" style="width: 734px;" class="fr-fic fr-dib"><span class="fr-inner"><span contenteditable="true" id="isPasted">Join us in Berlin and/or Boston and lets us RESHAPE the Future of Electronics, making it Additive, Sustainable, Hybrid, Wearable, and 3D - techblick.com</span></span></span></span></p><p id="isPasted"><strong>Table 1</strong> overviews the commercially available and under-development Henkel PTC ink range. Low voltage inks are formulated to self-regulate at voltages below 50 V. High voltage inks, identified by HV in the name, can be used for voltages above 50 V. Low and high voltage inks differ mostly by their sheet resistance. A non-conductive ink, NCI, is also available for each self- regulation temperature, allowing the printer to adjust the sheet resistance.</p><p><strong>Table 1.</strong> Henkel PTC ink range.</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk1MjAyMDI0NTc2LVNjcmVlbnNob3QgMjAyMy0wOS0yMCAwOTM2MjcucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 629px;" class="fr-fic fr-dib"></p><h3 id="isPasted"><strong>2 &nbsp; Typical Example of 9V, 60 °C, self-regulating demo heater</strong></h3><p><strong>&nbsp; &nbsp; &nbsp;2.1 &nbsp;Layout</strong></p><p><strong>Figure 2</strong> shows the exploded view for a typical PTC heater. The polyester substrate is an industry standard. A first layer of highly conductive silver ink tracks is printed, typically with LOCTITE ECI 1010. Two main areas can be identified: the busbars and the fingers. On the sides, the busbars carry the current and must be designed according to the maximum current peak to avoid local heating. The finer silver fingers give the interdigit structure and allow having all PTC elements in parallel. Then, the PTC ink, from LOCTITE ECI 8000 series is printed on top of the silver tracks as numerous independent elements. On top of the conductive inks, an insulating layer is mandatory. This layer can either be a printable dielectric or a laminated foil. As PTC inks are living materials with a variable resistance, the influence of the insulating layer should be closely monitored. It should not deteriorate the ink properties, such as PTC ratio and long-term reliability.</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk1MjAyMDY1NjE2LVNjcmVlbnNob3QgMjAyMy0wOS0yMCAwOTM3MDUucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 621px;" class="fr-fic fr-dib"></p><p>Figure 2. Exploded view of 9 V demo heater showcasing the four main components. For this 9 V self-regulating demo heater, substrate is PET 125 µm, silver ink is LOCTITE ECI 1010, PTC ink is LOCTITE ECI 8001 with self- regulation in the 55-60 °C range, and translucent dielectric UV-curing ink is LOCTITE EDAG PF-455BC.</p><p><strong>&nbsp; &nbsp; &nbsp;2.2 &nbsp;Typical Voltage Sweep Characterization</strong></p><p id="isPasted">Voltage sweep curves are characteristic of one self-regulation in a specific condition. Taping a heater on different surfaces, like a metallic plate or a foam, will give different results. For characterization purposes, it is interesting to characterize the heater on an insulating foam to expose potential limitations like hotspots or printing inhomogeneities.</p><p><strong>Figure 3</strong> shows the resistance and average surface temperature change with increasing applied voltage. Three typical zones of a self-regulating PTC heater are nicely exemplified.</p><p><strong>- Zone I</strong>,<strong>&nbsp;Heating-Up.</strong> Temperature increases with the increasing voltage thanks to the Joule effect until reaching the onset of self-regulation.<br id="isPasted"><strong>- Zone II</strong><strong>, Self-regulation</strong>. With the increasing voltage, resistance increases thanks to the volume expansion of the wax particles.<br><strong>- Zone III</strong>, <strong>Overruled PTC effect</strong>. The voltage is too high. The resistance cannot increase anymore. Temperature rises above the self-regulation, reaching the melting point of the wax. Melting of the wax brings the carbon particles closer and the resistance drop. Runaway may occur.</p><p>Applying 5, 8, or 10 V to the heater will give the same self-regulation temperature based on this voltage sweep. This is due to the sharp PTC effect around 60 °C. The higher the PTC ratio, the larger the self-regulation plateau. High PTC ratio of Henkel inks enables rapid heating than to high initial power.</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk1MjAyMTcwNTYyLVNjcmVlbnNob3QgMjAyMy0wOS0yMCAwOTM3NDgucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 553px;" class="fr-fic fr-dib"></p><p>Figure 3. Typical characterization curve of a self-regulating PTC heater. Temperature (grey curve) and resistance (red curve) are measured as a function of increasing voltage.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 730px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1699455002364-B-and-B-2024%28e-mail%29.jpg" style="width: 728px;" class="fr-fic fr-dib"><span class="fr-inner"><span contenteditable="true" id="isPasted">Join us in Berlin and/or Boston and lets us RESHAPE the Future of Electronics, making it Additive, Sustainable, Hybrid, Wearable, and 3D - techblick.com</span></span></span></span></p><h3 id="isPasted"><strong>3 &nbsp;Heater Initial Guidelines</strong></h3><p><strong>&nbsp; &nbsp; 3.1 &nbsp;Requirement Definition</strong></p><p>To start your self-regulating PTC heater project, you must have some crucial primary information:</p><ul><li>The driving voltage that will power your heater. It will be closely related to the spacing between two silver fingers and the resistance of one PTC unit. The higher the voltage, the higher should be the resistance of the PTC unit. It is possible either by increasing the distance between the silver fingers or increasing the sheet resistance of the PTC ink.</li><li>The initial heating power. To heat an object, you need a heat source with a higher temperature than the object and sufficient power to heat this object. If you have a low power hot heater, then the object will heat-up very slowly. Conversely, you may overrule the PTC effect if your heater is too powerful. Knowing the driving voltage and the initial heating power will allow the calculation of the resistance of the heater, 𝑅 = 𝑈2⁄𝑃. Voltage and resistance define the initial in-rush current 𝐼 = 𝑈⁄𝑅. Silver busbars must be designed according to the in-rush current.</li><li>The self-regulation temperature to choose the adapted PTC ink.</li><li>The heater dimension or available area.</li></ul><p>It will also be important to identify the heater integration and heat diffusion behavior early in the project as it strongly impacts the heater design and layout.</p><p><strong>&nbsp; &nbsp; &nbsp;3.2 &nbsp;Basic Design Rules and Calculations</strong></p><hr><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk1MjAyMzg5OTU5LVNjcmVlbnNob3QgMjAyMy0wOS0xOSAxNDQ1NTIucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 663px;" class="fr-fic fr-dib"></p><hr><h3>4 &nbsp;Accelerating Customer On-Boarding</h3><p>Developing self-regulating heaters requires a large range of expertise such as material, printing, circuit design, heat transfer, and integration. Following a methodology based on years of feedback enables a progressive learning curve and the identification of key parameters.&nbsp;</p><p><strong>Figure 4</strong> gives an overview of this methodology. If specific expertise is needed, Henkel team can bring external partners to the table for the success of customer projects.</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk1MjAyMjU5MzAyLVNjcmVlbnNob3QgMjAyMy0wOS0yMCAwOTM4MzIucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 641px;" class="fr-fic fr-dib"></p><p>Figure 4. Overview of Henkel PTC ink on-boarding methodology</p><p><span contenteditable="true" id="isPasted">Join us in Berlin and/or Boston and lets us RESHAPE the Future of Electronics, making it Additive, Sustainable, Hybrid, Wearable, and 3D - techblick.com</span></p><p><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1699455021093-B-and-B-2024%28small-LinkedIn+for-email%29.jpg" style="width: 724px;" class="fr-fic fr-dib"></p><p><span contenteditable="true" id="isPasted">Join us in Berlin and/or Boston and lets us RESHAPE the Future of Electronics, making it Additive, Sustainable, Hybrid, Wearable, and 3D - techblick.com</span></p>

Heaters are one of the most successful applications of printed electronics. At first they seem deceptively simple, yet their successful realization is in fact an art relying on the interplay of all the elements from the right material selection to right design, right printing, etc. Learn how here.

From Experiment to Final Print: Understanding Self-Regulation PTC Heaters

<p id="isPasted">Authors: Steliyan Vasilev<sup>1</sup>, Melanie Hoerr<sup>1</sup>, Michaela Kasdorf<sup>1</sup>, Sven Boehmer<sup>2</sup></p><p><em><sup>1</sup></em><em>3E Smart Solutions, Krefeld, Germany</em></p><p><em><sup>2</sup></em><em>ZSK Stickmaschinen GmbH, Krefeld, Germany</em></p><p><em>This article originally appeared </em><a href="https://www.techblick.com/post/optimizing-embroidered-conductive-traces-for-e-textiles" target="_blank" rel="noopener noreferrer"><em>here.</em></a></p><h3>1. Introduction</h3><p>Embroidery was historically a means of adorning fabrics with intricate patterns, a testament to human skill. However, in the modern era, this ancient art form has significantly evolved. In recent years, embroidery has undergone a profound transformation, emerging as a pioneering technology at the intersection of artistry and functionality. This article delves into the possibilities which embroidery offers for the production of Smart and E-Textiles, exploring technical intricacies, advantages, and challenges related to embroidered conductive traces.</p><p>&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0ODQ4Mjk4MjI0LVNjcmVlbnNob3QgMjAyMy0wOS0xNiAwNzU1MjIucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 649px;" class="fr-fic fr-dib"></p><p>Join us at TechBlick&#39;s Future of Electronics RESHAPED conference &amp; tradeshow in Berlin on 17-18 OCT 2023 - <a target="_blank" rel="noopener noreferrer" data-fr-linked="true" href="//www.techblick.com/electronicsreshaped" id="isPasted">www.techblick.com/electronicsreshaped</a></p><h3>2. Solutions for the E-Textiles Production Made Possible by Embroidery</h3><p>E-Textiles represent a fascinating synergy between traditional textiles and modern technology, serving diverse sectors like automotive, aerospace, sports and fitness, medical, home textiles, and wearable technology. Thanks to the exceptional precision and high degree of automation of embroidery technology, it is ideal for integrating functional elements into textiles, such as sensors, actuators, antennas, or electrodes.&nbsp;By use of conductive threads and specialized attachments for automated integration of electronic components, embroidery techniques, originally developed for aesthetic purposes, now enable reliable and scalable E-Textiles production. Embroidery makes possible the following innovative solutions, among all:</p><ul><li>Integrating and Interfacing Electrical Components and PCBs</li></ul><h4><em>Semi-Automated Integration</em></h4><p>In decorative embroidery, the Appliqu&eacute; technique is utilized to attach pre-made textile patches to the carrier fabric. This same method can be used for semi-automatic placement of printed circuit boards (PCBs). After the manual placement and adjustment of the PCB, the embroidery machine takes over, automatically fixing it to the fabric and establishing the electrical connections at the interface pads.&nbsp;</p><h4><em>Automated Integration</em></h4><p>Embroidery machines equipped with automated Sequin Placement Devices can be configured to incorporate functional sequins into textiles (Fig. 1a). Functional sequins can be equipped with SMD soldered components, such as LEDs or RFID chips. For larger circuit boards, whether rigid or flexible, embroidery machines fitted with automated PCB Placement Devices can precisely position and secure the PCBs to the textile (Fig. 1b), followed by embroidery of the electrical connections. Automated integration is especially valuable for achieving reliability and reproducibility in the production of E-Textiles on a large scale.</p><ul><li>&nbsp;Embroidery of Complete Electrical Circuits</li></ul><p>By embroidering conductive traces onto fabric, placed PCBs and peripheral components can be electrically connected to each other, as well as to power sources or external circuitry. This approach allows for the automated integration of complete electrical circuits into textiles during a single production step.</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0ODQ4MzM4OTEwLVNjcmVlbnNob3QgMjAyMy0wOS0xNiAwNzA4NDAucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 689px;" class="fr-fic fr-dib"></p><p><em id="isPasted">Figure&nbsp;</em><em>1</em><em>&nbsp;Automated integration of functional LED sequins (a) and PCBs (b) by using automated Sequin Placement Device and PCB Placement Device from ZSK Stickmaschinen GmbH</em></p><ul id="isPasted"><li>&nbsp;Integration of Conductive Fibers and Wires</li></ul><p>Tailored Wire Placement (TWP) and Tailored Fiber Placement (TFP) techniques allow precise conductor placement for applications such as illumination, textile-based heating, RFID antennas, and more.</p><ul><li>&nbsp;Embroidery of Conductive Areas</li></ul><p>With conductive threads, conductive areas in various shapes and sizes can be embroidered. These areas can serve a multitude of functions, including wide conductive traces, sensors, electrodes, and antennas, expanding applications from automotive control elements to advanced medical devices.</p><h3>3. Advantages of Embroidered Conductive Traces</h3><p>Embroidery of conductive traces has opened up new horizons for Smart and E-Textiles, driven by several distinct advantages:</p><ul><li>&nbsp;Versatility in Design and High Precision</li></ul><p>Embroidery offers unparalleled versatility in design. Complex patterns and intricate geometries become feasible, catering to diverse application needs. The precision achieved in embroidery ensures that these designs are replicated accurately and consistently.</p><ul><li>&nbsp; Flexibility and Breathability</li></ul><p>One of the standout features of embroidered conductive traces is their inherent flexibility. They easily integrate with the carrier fabric, preserving its natural drape. Unlike printed circuits, embroidered traces allow textiles to breathe, enhancing wearability in clothing and comfort in various applications.</p><ul><li>&nbsp;Durability and Washability</li></ul><p>Embroidered conductive traces exhibit impressive durability. They withstand the rigors of daily use and multiple washing cycles, remaining fully functional over extended periods. This longevity contributes to the reliability and sustainability of embroidered E-Textiles products.</p><ul><li>&nbsp;Enabling Direct Connection to Electrical Components and PCBs</li></ul><p>Embroidery facilitates the direct integration of conductive traces with electrical components and printed circuit boards (PCBs). This approach eliminates the need for additional connectors or complex wiring, enhancing the product&rsquo;s reliability and comfort and reducing production costs.</p><h3>4. Challenges and State-of-the-Art Solutions for Embroidered Conductive Traces</h3><p>While there are clear advantages to using embroidered conductive traces, there are also associated challenges. In the following sections, we will outline the primary challenges and present state-of-the-art solutions to address them.</p><p>&nbsp; &nbsp; &nbsp; &nbsp; a) &nbsp; Compensation for High Yarn Resistivity</p><p>One of the main challenges in utilizing conductive embroidery threads is their intrinsic high resistivity of up to a few hundred Ohms per meter. To address this challenge, several state-of-the-art solutions have emerged:</p><ul><li>&nbsp;<em>Multiple Passes and Use of Conductive Bobbin Thread&nbsp;</em></li></ul><p>A method to compensate for the high resistivity of the conductive thread is to embroider multiple passes using the so-called running stitch. Each pass adds to the overall conductivity, effectively acting like parallel resistors (Fig. 2a). Additionally, incorporating a conductive bobbin thread enhances conductivity by further reinforcing the electrical path (Fig. 2b). As an additional benefit, multiple embroidered passes compensate for the inhomogeneity in resistance throughout yarn length due to local damages in a single yarn pass during use, increasing the reliability of the E-Textiles product.</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0ODQ4NDA1MDAxLVNjcmVlbnNob3QgMjAyMy0wOS0xNiAwNzEwMTYucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 723px;" class="fr-fic fr-dib"></p><p><strong id="isPasted"><em>Figure 2</em></strong><em>&nbsp;Equivalent circuit of embroidered conductive trace with one, two, and three passes (a), and conductive embroidery (yellow) and bobbin (green) thread (b)</em></p><ul id="isPasted"><li><em>&nbsp;Conductive Traces Embroidered as Filled Areas</em></li></ul><p>An alternative approach for reducing resistivity is to embroider conductive traces as filled areas, using the fill stitch rather than the running stitch. The high density of stitches in the filled areas enhances the overall trace conductivity. To ensure sufficient electrical contact between the stitches along the stitch direction, an underlayer must be added beneath the fill stitch, angled to the primary stitch direction (Fig. 3) [1].</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0ODQ4NDU1NTMxLVNjcmVlbnNob3QgMjAyMy0wOS0xNiAwNzEwNTIucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 732px;" class="fr-fic fr-dib"></p><p><strong id="isPasted"><em>Figure 3</em></strong><em>&nbsp;Embroidered area with fill stitch without (a) and with a grid underlayer (b)</em></p><p>&nbsp; &nbsp; &nbsp; &nbsp; &nbsp;b) Avoiding Conductive Thread Damage during Embroidery</p><p>During embroidery, stitching directly into the conductive yarn can damage it, compromising electrical properties. Therefore, special attention must be given to the digitizing of the embroidery design to avoid placing stitches over previously embroidered threads as well as repetitive stitching in the same spot.</p><p>To mitigate this while embroidering multiple running stitch passes, a swing factor can be introduced in the digitizing program, altering the stitching path slightly with each pass. This minimizes localized stress on the yarn, preserving its integrity and conductivity. Fig. 4 illustrates a conductive trace with four passes and an added swing factor, shown as a visualization in the embroidery machine&rsquo;s programming software (a) along with a photograph of the embroidered trace (b).</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0ODQ4NDk4MjQ1LVNjcmVlbnNob3QgMjAyMy0wOS0xNiAwNzExMjAucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 731px;" class="fr-fic fr-dib"></p><p><strong id="isPasted"><em>Figure 4&nbsp;</em></strong><em>Conductive trace with four passes for increased conductivity and added swing factor, shown in the digitizing software (a) and after embroidery (b).</em></p><p><em>When adding a swing factor, corners pose a specific challenge, leading to repeated puncturing at the same location (Fig. 5a). Rounding corners in the embroidery design is essential, as it significantly reduces the risk of stitching into the yarn, maintaining its electrical properties (Fig. 5b) [1].</em></p><p><em><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0ODQ4NjIyNTQ5LVNjcmVlbnNob3QgMjAyMy0wOS0xNiAwNzEyMTQucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 704px;" class="fr-fic fr-dib"></em><strong id="isPasted"><em>Figure 5</em></strong><strong><em>&nbsp;</em></strong><em>Running stitch with three passes and an added swing factor, with multiple punctures in sharp edges (a) and without multiple punctures in rounded corners (b)</em></p><p>&nbsp; &nbsp; &nbsp; &nbsp; c) Enabling Crossing and Insulation of Conductive Traces</p><p>Complex E-Textiles designs often require multiple closely adjacent or intersecting conductive traces. Without proper insulation, unwanted electrical connections can occur&nbsp;when these traces come into contact. Adding non-conductive bridges between traces prevents unintended short circuits and maintains the desired electrical paths. Insulating bridges can be created by embroidering multiple layers of satin stitch with non-conductive thread, as depicted in Fig. 6a. It is crucial to ensure that the stitch directions of the bridge layers are angled in relation to the intersecting conductive traces.</p><p>Covering conductive traces with non-conductive thread can also be used for insulation towards the surrounding environment. Fig. 6b illustrates an example of covered conductive traces connected to moss-embroidered electrodes for body signal acquisition. The covering prevents direct contact with the skin outside the electrode areas. For applications requiring waterproofing of the conductive traces, seam sealer in the form of tape or liquid, or dispensed polymer coatings can be utilized.</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0ODQ4NjcxMzQwLVNjcmVlbnNob3QgMjAyMy0wOS0xNiAwNzEyNDAucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 702px;" class="fr-fic fr-dib"></p><p><strong id="isPasted"><em>Figure 6</em></strong><em>&nbsp;Covering conductive traces with non-conductive thread to create insulating bridges between intersecting traces (a) and as a method of insulation towards the surrounding environment (b).</em></p><h3>&nbsp;5. Conclusion</h3><p>The integration of conductive traces into textiles through embroidery offers a promising avenue for the development of Smart and E-Textiles. While the advantages of embroidered conductive traces make them a compelling choice for a wide range of applications, there are technical hurdles. Fortunately, various state-of-the-art solutions have been developed to address these challenges, ensuring that embroidered conductive traces can meet the demands of diverse applications.</p><p>&nbsp;As technology advances and the demand for Smart Textiles grows, continued research and innovation in the field of technical embroidery will be essential. With ongoing efforts to refine techniques and materials, we can expect to see even more sophisticated and reliable embroidered E-Textiles, opening up new possibilities in wearable technology, healthcare, fashion, and beyond.</p><p>&nbsp;<strong>References</strong></p><p>[1] McCann, J., &amp; Bryson, D. (2023). Smart Clothes and Wearable Technology, Second Edition. Elsevier.</p><p><br></p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjk0ODQ4NzExOTEwLVNjcmVlbnNob3QgMjAyMy0wOS0xNiAwNzU0NDgucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 671px;" class="fr-fic fr-dib"></p><p>Join us at TechBlick&#39;s Future of Electronics RESHAPED conference &amp; tradeshow in Berlin on 17-18 OCT 2023 - <a target="_blank" rel="noopener noreferrer" data-fr-linked="true" href="//www.techblick.com/electronicsreshaped" id="isPasted">www.techblick.com/electronicsreshaped</a></p>

Embroidery was historically a means of adorning fabrics with intricate patterns,a testament to human skill.In the modern era, this ancient art form has significantly evolved, becoming a pioneering tech at the intersection of artistry & functionality. Learn here about Embroidered Electronics Textiles

Optimizing Embroidered Conductive Traces for E-Textiles

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In this article you will learn more about liquid metals, a material that never ceases to amaze. It is water-like at room temperature but with metallic properties. Here you will see how researchers want to make them printable or turn them into conductive, stretchable, and washable fibers for e-textiles.  

Liquid metals: a material that never ceases to amaze

<p id="isPasted">Mass manufacturing electronic textiles and in doing so combining textile fibers/garments as well as textile based wiring and sensors with PCB electronics is no easy task. A critical manufacturing challenge here has always been the creation of a reliable high-quality connection between textile wiring/sensors and PCBs/rigid components using a mass manufacturing machine. ZSK has innovated to solve this issue for embroidered electronic textiles. &nbsp;This article originally appeared <a href="https://www.techblick.com/post/embrioded-electronic-textiles-solving-the-textile-to-pcb-and-ecosystem-challenges" rel="noopener noreferrer" target="_blank">here.</a></p><p>ZSK will be exhibiting in Berlin at TechBlick&#39;s event on RESHAPING ELECTRONICS. &nbsp;Please join us and the entire global community on 17-18 OCT 2023. Lear more here <a data-hook="linkViewer" href="https://www.techblick.com/electronicsreshaped" rel="noopener noreferrer" target="_blank"><u>https://www.techblick.com/electronicsreshaped</u></a>&nbsp;</p><div data-hook="rcv-block3" type="paragraph"><br></div><p><a href="https://www.techblick.com/electronicsreshaped" rel="noopener noreferrer" target="_blank"></a></p><div data-hook="imageViewer" tabindex="0"><a href="https://www.techblick.com/electronicsreshaped" rel="noopener noreferrer" target="_blank"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg2MTI2MjU3ODA0LTE2ODYxMjYyNTc4MDQucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="" data-pin-media="https://static.wixstatic.com/media/634751_9cf1c10eb91548198a7b527d61b55af7~mv2.jpg/v1/fill/w_1135,h_281,al_c,lg_1,q_80/634751_9cf1c10eb91548198a7b527d61b55af7~mv2.jpg" class="fr-fic fr-dii"></a></div><p><br></p><div data-hook="rcv-block6" type="image"><br></div><p><strong>Solving the textile-to-PCB connection issue</strong></p><p>As you can see in slide [1], typically PCBs do not lend themselves well to embroidery of electronics. This is because one often has loose connections, because the high thickness and the sharp edges act as failure points and because the large holes allow movement which loosens the connections. This means that it is not easy to achieve automatic manufacturing with standard PCBs in a reliable way.</p><p>This is why - as shown in slide [2] - ZSK developed the ZSK E-Tex-Board, which addresses the above mentioned issues, optimizing the board geometry (hole size, smooth edges, thickness, outer line design, etc) for mass embroidered e-textiles combining textiles wiring/sensors with PCBs.&nbsp;</p><p>As shown in slide [3], these special boards are also compatible with automatic placement machines, enabling a fully automatic manufacturing of e-textiles. This is an important step towards the realization of mass embroidered electronic textiles.&nbsp;</p><p>These PCBs - together with the ZSK&rsquo;s F-head for their embroidery machine - enable interesting opportunities. In the F-head, one can embroider the conductive threads with textile/garment to create wiring in the textiles. Using this head, one can also embroider insulating areas as needed, creating cross-overs which vastly improve wiring possibilities in tight spaces.&nbsp;</p><p>An example of a full system with embroidered conductive threads [wires] as well as crossovers and a stitched PCBs are shown in slide [3], showing how these innovations bring the entire system together, from conductive yarns to insulating to textile garments to PCBs and electronic components like LEDs etc</p><div data-hook="rcv-block18" type="paragraph"><br></div><p><strong>Solving the ecosystem issue</strong></p><p>ZSK has multiple other embroidery heads for different purposes [K-head for ECG and other sensors based on the moss embroidery and W-head for laying down tubes, fibers etc]. What is however of importance in our view is that they also offer business model innovation</p><p>They have correctly realized that the e-textile ecosystem is still immature and full of players each offering only a small part of the full system, which makes it very difficult for a potential end user to develop projects.&nbsp;</p><p>To this end, they have launched 3E Smart Solutions - an in-house engineering team - to help companies develop their ideas, prototype them, find manufacturing partners, etc. This fills an important void and we expect will accelerate the development of this industry &nbsp;</p><div data-hook="rcv-block28" type="empty-line"><br></div><div data-hook="galleryViewer"><div data-key="pro-gallery-inner-container" tabindex="-1"><div data-hook="item-link-wrapper" data-id="6cf29513-5f7f-4179-8b8a-06517f1e9ccb_0" data-idx="0" tabindex="-1"><div data-hash="6cf29513-5f7f-4179-8b8a-06517f1e9ccb_0" data-hook="item-container" data-id="6cf29513-5f7f-4179-8b8a-06517f1e9ccb_0" 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Mass manufacturing electronic textiles and in doing so combining textile based wiring and sensors with PCB electronics is no easy task. In this article, you will learn about an innovative approach to enable embriodery of PCBs and conductive wiring/sensors in mass produced e-textiles 

Embrioded Electronic Textiles: Solving the textile-to-PCB and ecosystem challenges

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