WovenCircuits: A 3-Step Fabrication Process for Weaving Electric Circuit Layouts in Everyday Artefacts

Previous work explored techniques for creating woven e-textiles, emphasizing interactive input and output elements. However, the integration of electrical connections and circuitry remains underexplored. Using Research through Design (RtD), we present WovenCircuits, a design-led inquiry into combining traditional weaving methods with computational design on digital Jacquard looms to create woven circuit schematics. Through iterative design experiments, we developed a 3-step process and characterized three fabrication techniques to: 1) weave insulated electrodes, 2) integrate rigid components into fabric, and 3) create woven electrical connections. We further examined their electrical behaviour through key design factors and evaluated the effect of washability on resistance and dimensions. To demonstrate its potential, we designed and built six high-fidelity research products showcasing diverse applications in interactive everyday objects. Finally, we reflect on the design opportunities and limitations of WovenCircuits, contributing to the growing body of knowledge on woven e-textiles.