Transcutaneous Electrical Nerve Stimulation (TENS)
This case study highlights a project undertaken by E-Textile Wearables for a client developing an e-textile-based Transcutaneous Electrical Nerve Stimulation (TENS) kinesiology tape. The engagement focused on transforming an early-stage concept into a more practical and manufacturable product direction.
E-Textile Wearables
3/30/20262 min read
Duration: 8 - 10 months
Year of Development: 2024 / 2025
Client: Lectra Technologies, INC. (Lectra.tech)
Application: Transcutaneous Electrical Nerve Stimulation (TENS)
”Ishan, Kosala, and the rest of the E-Textile Wearables team were critical for us to be able to hit our product development timelines. They operated in an extremely efficient manner throughout the entire project, and we are happy to work with them again.”
Jake Henry
Co-Founder, Lectra Technologies
Confidentiality Note
The client’s specific end-use application, algorithms, data-processing methods, commercial strategy, and product-specific requirements are protected under a non-disclosure agreement and have not been disclosed on this page. This case study presents only E-Textile Wearables’ general technologies, development methods, proprietary platforms, and e-textile integration expertise.
A video of the client testing the 1st version of the Tape E-Textile Wearables produced
Project Background
Development Scope
E-Textile Wearables carried out a focused product-development program to evaluate multiple technical approaches that E-Textile Wearables has used previously on other similar products and identify the most practical direction for the intended application. This included assessing several concepts using different e-textile materials, integration methods, and system configurations.
As part of the development, we evaluated alternative approaches for integrating the required wearable functionality while maintaining reliable interaction between the textile components and the external control system.
The overall development effort focused on improving functionality, comfort, reliability, integration quality, and manufacturability, while progressing the product from an early-stage prototype toward a more refined and robust product architecture.
Key Engineering Challenges
This application involved several e-textile engineering challenges that required iterative prototyping, testing, and refinement.
The key challenges included:
Improving user comfort during operation.
Achieving consistent and reliable performance across the intended application area.
Developing a versatile product design suitable for different use conditions.
Evaluating alternative material and integration approaches.
Creating a reliable interface between the wearable component and the external control system while supporting repeated use.
These challenges were addressed through multiple development iterations, technical evaluations, and design refinements, resulting in a solution that met the client’s expectations for the project stage.
Project Results and Handover
The project successfully progressed from very early-stage prototyping to a more advanced product-development and validation stage.
At handover, the client received the developed product direction together with the relevant technical documentation and supporting information required to support future product development and manufacturing activities.
The resulting solution was a more refined and application-focused e-textile product designed to improve user comfort, functional performance, reliability, and manufacturability.
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The client approached E-Textile Wearables with an early-stage manually developed prototype and the goal of converting the concept into a practical, product-ready solution. While the initial prototype demonstrated the potential of the idea, it also had several technical and manufacturability limitations that needed to be resolved before the product could progress further.
The target application required the tape to function reliably on skin for up to three consecutive days under demanding real-world conditions, including heavy perspiration, swimming, and high-movement activities such as running.
E-Textile Wearables was responsible for the e-textile technology integration and development of the tape platform. The power module development and FDA-related activities were handled separately by another development party engaged by the client.
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