Smart textile development through surface-mount resistor integrated E-yarns for efficient thermal performance

Advances in conductive materials and electronic devices are allowing the development of next-generation wearable electronics, where electronic yarns act as fundamental components of smart textiles. This study presents a resistive heating textile platform based on surface-mount device (SMD) integrated electronic yarn, demonstrated through electrically heated cotton socks. Precision SMD resistors embedded within silver-coated Vectran yarn provide controlled and uniform heat generation while maintaining textile flexibility. The thermal output is governed by the resistance of integrated components, with surface temperatures increasing from 42 °C at 3 V to 62.5 °C at 5 V. Systematic evaluation under different voltage levels, mechanical strain, operating durations, and input power conditions demonstrated predictable and nearly linear thermal behaviors which enables a controllable and energy-efficient heating performance. Mechanical durability and washing tests confirmed the feasibility of the system for wearable use; however, electrical resistance increased significantly after repeated laundering ( p < 0.001), indicating the need for improved encapsulation for long-term stability. Overall, this work establishes a scalable platform for wearable heating and physiological sensing in practical smart textile systems.