The research is aimed at developing appropriate technology necessary to produce three-dimensional molded garments to produce low-cost combat uniforms with effective barrier characteristics, using minimal joining. The system being developed is called Robotic Fiber Assembly and Control (RFAC) system. RFAC system will allow the incorporation of fibers, powders, or other appropriate additives into the garment systems. The additives may identify, measure, absorb, and/or deactivate chemical/biological agents. In the RFAC system deposition of melt-blown fibers on an appropriate mold is controlled by a six-axis industrial robot. The system allows precise control of fiber orientation distribution, fiber diameter distributions, and pore size distribution.

Fiber actuators are capable of dimensional change under the applied electrical field. Dielectric elastomer-based prototype fiber actuators have been developed using commercially available dielectric elastomer tubes and by applying appropriate compliant electrodes to the inner cavity and outer walls of these tubes. The force and displacement generated by such actuators have been studied under different isometric conditions and as a function of the applied electric field. The actuation characteristics such as axial strains, radial strains, and actuation blocking forces produced in the prototype upon actuation were studied. Actuation strain and blocking force are strongly influenced by the applied prestrain and have a parabolic relationship to the applied electric field. High actuation strains (>50%) are currently afforded by dielectric elastomers at relatively high electric fields (>50 V/µm). A new class of electroactive polymers, suitable for fiber formation, have been developed by incorporating low-volatility, aliphatic-rich solvent into a nanostructured triblock copolymer yielding physically crosslinked micellar networks that exhibit excellent displacement under an external electric field. Ultrahigh areal actuation strains (>200%) at significantly reduced electric fields (<40 V/µm) has been achieved.

Fabric-based electrical circuits are fundamental to electronic textile products of the future. The objective of the current research is to develop fabric-based electrical circuits by interlacing conducting and non-conducting threads into woven textile structures for civilians as well as military applications. Wired interconnections between different devices attached to the conducting elements of these circuits are made by weaving conductive threads so that they follow desired electrical circuit designs. In a woven electrically conductive network, routing of electrical signals is achieved by the formation of effective electrical interconnects and disconnects. Resistance welding is identified as one of the most effective means of producing crossover point interconnects and disconnects. These circuits are evaluated for signal integrity issues (crosstalk, etc.). Two new thread structures – coaxial and twisted Pair copper threads to minimize cross talk have been developed and evaluated. Significant reductions in crosstalk were obtained with the coaxial and twisted pair thread structures when compared with bare copper thread or insulated conductive threads.