Periodic Reporting for period 1 - TextrodeMisc (TextrodeMisc – TEXtile elecTRODE Matrix for Improved Surface eleCtromyography signal quality and usability in applications for people with limb loss)
Periodo di rendicontazione: 2023-09-01 al 2025-09-30
Phantom limb pain and difficulties in controlling prosthetic limbs remain everyday challenges for many people living with limb loss. Even when advanced prosthetic devices are available, their benefit depends on reliable communication between the user’s muscles and the electronics that interpret their intentions. Regarding therapies for phantom limb pain, this communication is often mediated by gel-based electrodes that must be carefully placed on the skin in a clinic. They work well in controlled settings, but they are messy to apply, uncomfortable over long periods, and are designed for single use. For home-based rehabilitation and long-term monitoring, this is an unsatisfying situation.
In recent years, textile electrodes, fabrics that can sense muscle activity, have emerged as a promising alternative. They can be integrated into comfortable garments and bands, potentially allowing people to put on their “sensing interface” as easily as a sleeve or a sock. However, current textile electrodes still face two critical limitations. First, they struggle to maintain a stable, low-impedance contact with the skin, especially during movement or sweating. Second, their durability under repeated use and washing is often poor. These shortcomings limit their use in demanding applications such as home-based phantom limb pain therapy and precise prosthesis control.
The TextrodeMisc project addressed this gap by developing textile-integrated, gel-free electrode matrices specifically tailored for people with limb loss. Its overall objective is to create a reusable “textrode” band that combines three properties: strong and comfortable adhesion to the skin, stable electrical performance over many use and wash cycles, and ease of self-application without clinical assistance. By achieving these goals, the project made advanced sEMG-based therapies and prosthetic control completely self-administered and more practical in everyday life rather than only in specialised laboratories or hospitals.
To reach this objective, the project brought together advanced materials science, smart textile engineering, and prosthetics. On the materials side, it explored new combinations of soft elastomers and high-conductivity nanomaterials such as MXenes, together with bio-inspired surface structures. These tiny patterns were designed to increase the actual contact area with the skin and to create a gentle “grip” without the use of aggressive adhesives. In parallel, eco-friendly interfacial chemistries were developed to strengthen the link between the sensing layer and the textile substrate, so that performance was maintained stretching, bending, and laundering.
On the textile and device side, these improved electrodes were arranged in configurable matrices that can capture detailed patterns of muscle activity on the residual limb. The matrices were designed to work with existing high-density sEMG hardware, but in a format that users can don and align themselves. This requires careful attention not only to electrical performance, but also to comfort, fit, and the practical realities of putting on and taking off the device every day.
The pathway to impact progressed from laboratory benchmarks to human-centred evaluation. The project first established transparent test methods for adhesion, washability and skin–electrode impedance, so that different designs can be compared fairly. Then, prototypes were evaluated in controlled sEMG recordings on healthy volunteers. In this way, the technical work ensured that the textrode matrix responds to real needs and constraints in home and clinical environments.
The project outcome delivered several layers of impact. For individuals, more comfortable and reliable electrodes could make home-based phantom limb pain treatment and prosthesis training easier to sustain, improving quality of life and autonomy. For healthcare systems, reusable, wash-durable textile electrodes can reduce reliance on single-use consumables and clinic-bound procedures, supporting a shift towards person-centred, decentralised care. For European industry and research, the project delivered open evaluation protocols, materials recipes and design concepts that can be adapted for other wearable applications, from sports and rehabilitation to long-term monitoring of chronic conditions. Finally, by prioritising reusability, bio-derived modifiers and safer processing routes, the work contributed to broader European ambitions around sustainable, digital health technologies.[
In recent years, textile electrodes, fabrics that can sense muscle activity, have emerged as a promising alternative. They can be integrated into comfortable garments and bands, potentially allowing people to put on their “sensing interface” as easily as a sleeve or a sock. However, current textile electrodes still face two critical limitations. First, they struggle to maintain a stable, low-impedance contact with the skin, especially during movement or sweating. Second, their durability under repeated use and washing is often poor. These shortcomings limit their use in demanding applications such as home-based phantom limb pain therapy and precise prosthesis control.
The TextrodeMisc project addressed this gap by developing textile-integrated, gel-free electrode matrices specifically tailored for people with limb loss. Its overall objective is to create a reusable “textrode” band that combines three properties: strong and comfortable adhesion to the skin, stable electrical performance over many use and wash cycles, and ease of self-application without clinical assistance. By achieving these goals, the project made advanced sEMG-based therapies and prosthetic control completely self-administered and more practical in everyday life rather than only in specialised laboratories or hospitals.
To reach this objective, the project brought together advanced materials science, smart textile engineering, and prosthetics. On the materials side, it explored new combinations of soft elastomers and high-conductivity nanomaterials such as MXenes, together with bio-inspired surface structures. These tiny patterns were designed to increase the actual contact area with the skin and to create a gentle “grip” without the use of aggressive adhesives. In parallel, eco-friendly interfacial chemistries were developed to strengthen the link between the sensing layer and the textile substrate, so that performance was maintained stretching, bending, and laundering.
On the textile and device side, these improved electrodes were arranged in configurable matrices that can capture detailed patterns of muscle activity on the residual limb. The matrices were designed to work with existing high-density sEMG hardware, but in a format that users can don and align themselves. This requires careful attention not only to electrical performance, but also to comfort, fit, and the practical realities of putting on and taking off the device every day.
The pathway to impact progressed from laboratory benchmarks to human-centred evaluation. The project first established transparent test methods for adhesion, washability and skin–electrode impedance, so that different designs can be compared fairly. Then, prototypes were evaluated in controlled sEMG recordings on healthy volunteers. In this way, the technical work ensured that the textrode matrix responds to real needs and constraints in home and clinical environments.
The project outcome delivered several layers of impact. For individuals, more comfortable and reliable electrodes could make home-based phantom limb pain treatment and prosthesis training easier to sustain, improving quality of life and autonomy. For healthcare systems, reusable, wash-durable textile electrodes can reduce reliance on single-use consumables and clinic-bound procedures, supporting a shift towards person-centred, decentralised care. For European industry and research, the project delivered open evaluation protocols, materials recipes and design concepts that can be adapted for other wearable applications, from sports and rehabilitation to long-term monitoring of chronic conditions. Finally, by prioritising reusability, bio-derived modifiers and safer processing routes, the work contributed to broader European ambitions around sustainable, digital health technologies.[
During the project, the research progressed from conceptual materials design to functional prototypes of reusable, textile-integrated dry electrodes for surface electromyography (sEMG). This work combined advanced materials formulation, textile engineering and electrophysiological testing, addressing two longstanding challenges in wearable sEMG applications: achieving stable skin–electrode contact and enabling durable, gel-free operation suitable for home use.
The first stage focused on materials development and optimisation. The project established several new electrode systems based on MXene–elastomer composites, complemented by a carbon-black/Ecoflex reference formulation that delivered robust, reproducible conductivity on textile substrates. Across all material systems, the textile base layer was reinforced using a tannic-acid pretreatment, confirmed by FTIR, which introduced additional functional groups and markedly improved coating adhesion.
To address the difficulty of forming reproducible skin contact, the project introduced a set of biomimetic surface-engineering strategies. Using laser-cut and machined molds, patterned Ecoflex layers featuring micro-pattern arrays were fabricated and laminated onto the conductive coatings. These engineered topographies increased the effective surface area, promoted more stable adhesion, and lowered electrode–skin impedance relative to flat, untreated controls.
Prototype fabrication progressed from individual electrodes to multi-electrode “textrode” matrices. Single electrodes were integrated with embroidered silver-yarn transmission lines and subsequently assembled into matrix layouts suitable for forearm sEMG, including 4×4 and 2×8 configurations. All matrices were manufactured with consistent spacing, stable connector interfaces compatible with standard sEMG hardware, and verified continuity and mechanical robustness across units.
A comprehensive set of characterisation and evaluation procedures was performed. Impedance measurements using two- and three-electrode setups showed that the best MXene-based designs approached the performance of commercial Ag/AgCl gel electrodes within the 10–1000 Hz band relevant for sEMG. Skin-contact impedance tests demonstrated significant reductions for modified MXene variants relative to baseline Ecoflex systems. Adhesion and peel-force testing confirmed that biomimetic surface patterns improved adhesion over flat controls and retained most of this effect over repeated cycles. Durability assessments, including laundry testing, repeated peeling, and visual/optical inspections, verified that multilayer MXene textiles remained functional after multiple wash cycles and extended storage.
Pilot sEMG recordings were conducted with healthy volunteers using standardised muscle gestures and electrode placements. Across these tests, the electrodes delivered signal quality comparable to stainless-steel dome electrodes and superior to Ag-fabric controls under matched conditions. Motion artefacts were notably reduced due to improved adhesion and surface stability, demonstrating readiness for larger-scale volunteer studies.
The project resulted in several key technical achievements. Three complementary MXene-based conductive systems suitable for textile integration were developed, alongside bio-derived modifiers that enhanced adhesion, dispersibility and interface stability. Robust biomimetic adhesive topographies were fabricated, significantly improving electrode–skin contact. Reusable textile-integrated electrodes and electrode matrices were successfully created, all compatible with clinical and research-grade sEMG tools. The best-performing dry electrodes achieved near-Ag/AgCl performance without the need for gels, supporting self-administration and home use. Finally, a standardised evaluation framework for impedance, adhesion, durability and signal quality was established.
Together, these achievements provide a technical foundation for the next phase of development: expanded healthy-volunteer testing, followed by pilot studies in phantom limb pain interventions and prosthetic control applications.
The first stage focused on materials development and optimisation. The project established several new electrode systems based on MXene–elastomer composites, complemented by a carbon-black/Ecoflex reference formulation that delivered robust, reproducible conductivity on textile substrates. Across all material systems, the textile base layer was reinforced using a tannic-acid pretreatment, confirmed by FTIR, which introduced additional functional groups and markedly improved coating adhesion.
To address the difficulty of forming reproducible skin contact, the project introduced a set of biomimetic surface-engineering strategies. Using laser-cut and machined molds, patterned Ecoflex layers featuring micro-pattern arrays were fabricated and laminated onto the conductive coatings. These engineered topographies increased the effective surface area, promoted more stable adhesion, and lowered electrode–skin impedance relative to flat, untreated controls.
Prototype fabrication progressed from individual electrodes to multi-electrode “textrode” matrices. Single electrodes were integrated with embroidered silver-yarn transmission lines and subsequently assembled into matrix layouts suitable for forearm sEMG, including 4×4 and 2×8 configurations. All matrices were manufactured with consistent spacing, stable connector interfaces compatible with standard sEMG hardware, and verified continuity and mechanical robustness across units.
A comprehensive set of characterisation and evaluation procedures was performed. Impedance measurements using two- and three-electrode setups showed that the best MXene-based designs approached the performance of commercial Ag/AgCl gel electrodes within the 10–1000 Hz band relevant for sEMG. Skin-contact impedance tests demonstrated significant reductions for modified MXene variants relative to baseline Ecoflex systems. Adhesion and peel-force testing confirmed that biomimetic surface patterns improved adhesion over flat controls and retained most of this effect over repeated cycles. Durability assessments, including laundry testing, repeated peeling, and visual/optical inspections, verified that multilayer MXene textiles remained functional after multiple wash cycles and extended storage.
Pilot sEMG recordings were conducted with healthy volunteers using standardised muscle gestures and electrode placements. Across these tests, the electrodes delivered signal quality comparable to stainless-steel dome electrodes and superior to Ag-fabric controls under matched conditions. Motion artefacts were notably reduced due to improved adhesion and surface stability, demonstrating readiness for larger-scale volunteer studies.
The project resulted in several key technical achievements. Three complementary MXene-based conductive systems suitable for textile integration were developed, alongside bio-derived modifiers that enhanced adhesion, dispersibility and interface stability. Robust biomimetic adhesive topographies were fabricated, significantly improving electrode–skin contact. Reusable textile-integrated electrodes and electrode matrices were successfully created, all compatible with clinical and research-grade sEMG tools. The best-performing dry electrodes achieved near-Ag/AgCl performance without the need for gels, supporting self-administration and home use. Finally, a standardised evaluation framework for impedance, adhesion, durability and signal quality was established.
Together, these achievements provide a technical foundation for the next phase of development: expanded healthy-volunteer testing, followed by pilot studies in phantom limb pain interventions and prosthetic control applications.
The project has advanced the field of wearable surface electromyography (sEMG) by developing durable, reusable, textile-integrated dry electrodes that achieve signal quality comparable to traditional gel electrodes, while eliminating the need for gels, professional placement or single-use consumables. This represents a significant improvement in usability and sustainability for home-based motor-control applications and rehabilitation technologies.
The project generated several scientific and technological breakthroughs that move beyond the current state of the art. First, three new electrode material classes were developed, each offering improvements in adhesion, dispersibility and impedance. These advances expanded MXene processing into non-polar elastomers and created a new materials space for soft electronics. Second, robust textile-integrated electrode structures and matrix arrays were established using multilayer composites mounted on soft textile carriers with embroidery-based routing. These systems were made compatible with clinical and research-grade sEMG hardware and maintained performance after repeated use. Third, the project demonstrated that the best-performing MXene dry electrodes can deliver sEMG signals comparable to commercial Ag/AgCl gel electrodes, overcoming typical issues of impedance drift and adhesion faced by current textile electrodes. Fourth, the work verified reusability and early long-term durability through mechanical peeling tests, wash cycles and real-time ageing, addressing one of the main shortcomings of existing textile-based sensors.
These technical achievements had meaningful implications for health, digitalisation and sustainability. In home-based rehabilitation, stable and reusable dry electrodes can support self-administered phantom limb pain therapy and motor-control training, reducing dependence on frequent clinic visits. In next-generation prosthetic control, improved signal quality and comfort can strengthen pattern-recognition strategies and enable more natural human–machine interfaces. In digital health and remote monitoring, reliable long-term sEMG from textiles opens opportunities in telemedicine, sports technology, occupational health and personalised recovery. From a sustainability perspective, the shift to reusable, gel-free electrodes was aligned with European Green Deal priorities by reducing chemical waste, eliminating single-use consumables and supporting safer solvent systems.
To progress towards broader adoption and real-world deployment, several enabling steps were anticipated. Further research and validation with larger healthy-volunteer datasets were recognised as necessary to consolidate evidence of non-inferiority to gel electrodes, while extended durability testing would build confidence for medical use. Demonstration and field testing in rehabilitation and prosthetic control settings provided practical evidence of usability, user acceptance and workflow integration. Industrial collaboration will be essential for manufacturing scale-up, cost evaluation and ensuring consistent quality. Regulatory and standardisation support can guide testing protocols, such as adhesion, wash durability, biocompatibility and electrical safety, and assist in navigating medical device approval pathways. Clear intellectual property and commercialisation strategies will also support industry partnerships while maintaining accessibility for research applications.
Overall, the project delivered reusable, comfortable and high-performance textile electrodes that can realistically be used in people’s homes, marking a substantial advance for assistive technologies and digital health. The results contributed to several broader European priorities: enabling trustworthy biosignal acquisition for the digital age; reducing waste and supporting circular materials aligned with the European Green Deal; improving efficiency and reducing healthcare burdens in line with an economy that works for people; and enhancing quality of life for individuals with limb loss through safer, self-managed rehabilitation options. Taken together, these achievements laid a strong foundation for scalable and sustainable wearable bioelectronics, with promising pathways toward clinical translation, commercial development and broad application across healthcare, sports and everyday life.
The project generated several scientific and technological breakthroughs that move beyond the current state of the art. First, three new electrode material classes were developed, each offering improvements in adhesion, dispersibility and impedance. These advances expanded MXene processing into non-polar elastomers and created a new materials space for soft electronics. Second, robust textile-integrated electrode structures and matrix arrays were established using multilayer composites mounted on soft textile carriers with embroidery-based routing. These systems were made compatible with clinical and research-grade sEMG hardware and maintained performance after repeated use. Third, the project demonstrated that the best-performing MXene dry electrodes can deliver sEMG signals comparable to commercial Ag/AgCl gel electrodes, overcoming typical issues of impedance drift and adhesion faced by current textile electrodes. Fourth, the work verified reusability and early long-term durability through mechanical peeling tests, wash cycles and real-time ageing, addressing one of the main shortcomings of existing textile-based sensors.
These technical achievements had meaningful implications for health, digitalisation and sustainability. In home-based rehabilitation, stable and reusable dry electrodes can support self-administered phantom limb pain therapy and motor-control training, reducing dependence on frequent clinic visits. In next-generation prosthetic control, improved signal quality and comfort can strengthen pattern-recognition strategies and enable more natural human–machine interfaces. In digital health and remote monitoring, reliable long-term sEMG from textiles opens opportunities in telemedicine, sports technology, occupational health and personalised recovery. From a sustainability perspective, the shift to reusable, gel-free electrodes was aligned with European Green Deal priorities by reducing chemical waste, eliminating single-use consumables and supporting safer solvent systems.
To progress towards broader adoption and real-world deployment, several enabling steps were anticipated. Further research and validation with larger healthy-volunteer datasets were recognised as necessary to consolidate evidence of non-inferiority to gel electrodes, while extended durability testing would build confidence for medical use. Demonstration and field testing in rehabilitation and prosthetic control settings provided practical evidence of usability, user acceptance and workflow integration. Industrial collaboration will be essential for manufacturing scale-up, cost evaluation and ensuring consistent quality. Regulatory and standardisation support can guide testing protocols, such as adhesion, wash durability, biocompatibility and electrical safety, and assist in navigating medical device approval pathways. Clear intellectual property and commercialisation strategies will also support industry partnerships while maintaining accessibility for research applications.
Overall, the project delivered reusable, comfortable and high-performance textile electrodes that can realistically be used in people’s homes, marking a substantial advance for assistive technologies and digital health. The results contributed to several broader European priorities: enabling trustworthy biosignal acquisition for the digital age; reducing waste and supporting circular materials aligned with the European Green Deal; improving efficiency and reducing healthcare burdens in line with an economy that works for people; and enhancing quality of life for individuals with limb loss through safer, self-managed rehabilitation options. Taken together, these achievements laid a strong foundation for scalable and sustainable wearable bioelectronics, with promising pathways toward clinical translation, commercial development and broad application across healthcare, sports and everyday life.