Crafting Research Products through Digital Machine Embroidery

Wearables combine practical and conceptual challenges related to electronics, clothing and interaction design. Research through design in this area is commonly done iteratively through prototypes of increasing levels of fidelity, often relying on manual fabrication. However, manual fabrication presents challenges when comparing prototypes due to their varying levels of realization and the inaccuracy of reproductions. We discuss how using digital machine embroidery, combined with chemical embroidery technique, supports fabricating consistent high-fidelity prototypes for soft wearables in the form of research products. Our approach involves creating the textile substrate together with integrating and embedding electronic components through a unified process whilst keeping high control over alterations between prototypes. We illustrate this approach through the design process of the Smart Sock, a sensorized sock for rehabilitation. We detail the challenges behind our process and reflect on the opportunities emerging from using digital machine and chemical embroidery techniques combined to craft research products.