Tuning the Electromechanical Performance of Knitted Strain Sensors through Stitch Variation

Knitted fabrics are a promising platform for wearable strain sensors owing to their flexibility, stretchability, and comfort. However, the influence of stitch variation on the sensing performance has not been systematically investigated. This study explores plain jersey, cross-tuck, and cross-miss structures knitted from composite elastomeric yarns to tailor stitch and performance relationships. Structural analysis revealed that stitch types strongly affect areal density, loop geometry, and initial electrical resistance. Mechanical testing showed that plain jersey structures required a higher force to deform, while cross-tuck and cross-miss provided greater extensibility. Electromechanical evaluation demonstrated distinct responses: plain jersey exhibited the highest sensitivity at low strains but became unstable beyond 30%; cross-tuck offered consistent sensing up to 40% strain; and cross-miss maintained stable, reversible signals up to 60% strain with low hysteresis. Wearable trials validated these trends, identifying plain jersey as optimal for wrist motion, a cross-tuck for elbow bending, and a cross-miss for knee movement. These results highlight stitch engineering as an effective design strategy to tailor knitted strain sensors for application-specific wearable electronics.