Wearable EMG Band with Dry Electrodes
A flexible, textile-integrated surface EMG band developed using our established EMG platform, dry electrodes, proprietary conductive pathways, and proven textile-electronic integration methods. This project demonstrates how an existing sensing platform can be adapted efficiently into a customized wearable form factor for a specific customer application.
E-Textile Wearables
Development Period: 2025–2026
Client: Confidential
Application: Wearable biosensing and surface electromyography (EMG)
Confidentiality Note
The customer’s identity, intended application, detailed specifications, and commercially sensitive project information are protected by confidentiality requirements. The information here covers our internally developed EMG platform, our background IP, and integration and testing activities that can be publicly disclosed and are not specific to the customer's design.
Flexible textile EMG band with four integrated dry-electrode contact points.
Project Background
We initially developed this wearable EMG system as an internal technology platform for capturing muscle-activity signals through dry electrodes integrated into a flexible textile structure.
When a customer approached us with a related requirement, we customized our existing EMG sensing platform instead of developing an entirely new system. This allowed us to build upon previously validated sensing methods, proprietary conductive pathways, and established textile-to-electronics interconnections.
The customer’s identity and specific end-use application remain confidential. This page therefore focuses only on the high-level platform, development approach, and functional testing that can be publicly presented.
Functional testing of the dry-electrode EMG band during repeated hand and forearm muscle activation.
Development Scope
Stage 1 — Adapting Our Existing EMG Platform
The project began with our previously developed EMG electronics and signal-acquisition architecture.
Because the core platform was already available, the development team could focus on adapting the electrode configuration, textile structure, signal routing, and external interfaces for the required band format.
This reduced the amount of foundational development required and allowed functional prototypes to be prepared more efficiently.
Stage 2 — Integrating Dry Electrodes into the Band
Four dry electrode contact points were integrated into a narrow, flexible band designed to sit against the forearm.
The dry-electrode approach allows the system to collect surface electromyography signals without requiring traditional wet or gel-based electrodes. The textile band also helps position the electrodes against the required areas of the skin while providing a more wearable structure than a rigid sensor assembly.
The electrode arrangement was developed using our existing dry-electrode sensing platform and then adjusted for the band geometry and intended forearm placement.
Stage 3 — Conductive Pathway and Interconnection Integration
The electrodes were connected through our proprietary textile-integrated conductive pathway system.
These pathways carry the low-level signals from the electrode positions toward the external electronics while maintaining the flexibility of the band. The routing and connection areas were created using integration methods already developed through our earlier platform work.
The conductive pathways were then connected to the test electronics through established soft-to-hard interconnections. During functional testing, the band was connected to an external power and controller module, allowing the team to monitor the signals while the wearer performed repeated hand and forearm movements.
Stage 4 — Functional EMG Signal Testing
The completed band was tested on the forearm while the wearer repeatedly opened and closed the hand and activated different forearm muscle groups.
The testing confirmed that the integrated dry electrodes, conductive pathways, interconnections, and signal-acquisition platform could operate together as a complete functional system.
The video below shows the prototype being tested during repeated hand and forearm contractions.
Exploring the EMG Signal Data
The signals captured during testing can be explored through a separate interactive data page.
The interactive plot allows viewers to:
Switch between available EMG recordings
Review multiple electrode channels
Zoom into specific sections of the recordings
Compare changes in signal amplitude
Navigate through the recordings using the interactive range controls
The displayed recordings are engineering prototype data collected during functional testing. They are provided to demonstrate the platform’s signal-acquisition capability and are not intended to represent medical or diagnostic results.
Preview of the multi-channel EMG signals captured during functional prototype testing.
Key Engineering Challenges
This project did not introduce major first-of-kind engineering challenges because much of the technical foundation had already been developed and refined through our internal EMG platform work.
However, several important engineering considerations still had to be maintained during customization.
Maintaining Dry-Electrode Contact
Dry-electrode EMG systems depend on suitable contact between the electrodes and the wearer’s skin.
The electrode positions, band placement, and contact pressure therefore had to work together without making the wearable unnecessarily rigid or uncomfortable.
Preserving Signal Integrity
Surface EMG signals are relatively small and can be affected by movement, poor contact, pathway design, and electrical interference.
Our previously developed conductive pathway and interconnection architecture helped reduce these risks and provided a reliable foundation for the customized band.
Adapting the Platform Without Redesigning the Core System
The band geometry, electrode configuration, and external interfaces needed to be adapted for the customer while preserving the proven elements of the existing platform.
This platform-based approach allowed the customization work to concentrate on the customer-specific requirements instead of repeating the complete EMG development process.
Connecting with Our Other Wearable Platforms
This project builds upon several technologies used across our wider e-textile development work.
Like our ECG T-shirt project, the EMG band collects low-level biopotential signals through electrodes placed against the body. However, ECG is used to record the heart’s electrical activity, while EMG measures electrical activity associated with muscle activation.
The body-contact electrode knowledge developed through our TENS wearable projects is also relevant, although TENS systems deliver controlled electrical stimulation while EMG systems record naturally occurring muscle signals.
EMG sensing can also complement the movement data collected through systems such as our wearable motion capture garment project, creating opportunities for future wearable platforms that combine muscle-activity and movement information.
Together, these projects demonstrate our capability to develop different textile-integrated sensing and stimulation systems using shared conductive pathways, interconnections, electrode-integration methods, and electronic platforms.
Project Progress and Current Status
After completing the initial customized development and functional testing, we provided complimentary prototype samples to the confidential customer for independent evaluation.
The project has now progressed to its next stage. We are working toward a more customized version based on the customer’s specific requirements and the feedback generated during the initial evaluation.
Reusing our established EMG platform allowed us to reach this stage efficiently while reducing the technical uncertainty normally associated with developing a completely new wearable biosensing system.
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