Structural Design and Optimization of Knitted Heaters for Optimized Heat Distribution

Knitted heaters have attracted significant interest due to their flexibility and ease of integration into smart textile applications. However, uneven heat distribution remains a major challenge, leading to comfort issues and inefficient energy usage. This study presents an analytical, physics-based model that links the resistance, power distribution, and surface temperature of knitted heaters to key design parameters such as size, configuration, material properties, and knitting structure to establish guidelines for achieving a desired temperature rise over a specified surface area. The model was validated experimentally across a range of heaters (3–12 lines) arranged in ladder and diagonal configurations. Results showed good agreement between predictions and measurements for higher line counts (10–12), while larger deviations occurred in smaller heaters (3–5 lines) due to contact resistance and current losses. A prototype knitted wristband demonstrated physiologically relevant heating (>33 °C) under safe, low-voltage operation. These findings provide a quantitative design framework for optimizing knitted heaters and highlight their potential for scalable integration into wearable and therapeutic applications.