Using a PCB Layout Tool to Create Embroidered Circuits

Embroidery using conductive threads is an appealing method for creating circuits on fabric, with the embroidered threads forming traces and pads, and ICs and PCBs attached via several different methods including epoxy, snaps and stitches. However, embroidery software was designed for the look and feel of the stitches, not the electrical properties and manufacturability of embroidered circuits. The process remains largely an art form where one must trace lines, determine stitch density, freehand designs and hope the software places stitches in the right place. The goal of this project is to automate this process by using PCB design tools and custom software to convert the layout to an embroidery pattern. By automating the tool-flow from PCB layout to embroidery, we have improved the quality of the embroidered circuits, reduced the burden on the designer to have extensive embroidery knowledge, and taken first steps towards automated assembly of embroidered circuits.