All Knitted and Integrated Soft Wearable of High Stretchability and Sensitivity for Continuous Monitoring of Human Joint Motion

E‐textiles have recently gained significant traction in the development of soft wearables for healthcare applications. However, there have been limited works on wearable e‐textiles with embedded stretchable circuits. Here, stretchable conductive knits with tuneable macroscopic electrical and mechanical properties are developed by varying the yarn combination and the arrangement of stitch types at the meso‐scale. Highly extensible piezoresistive strain sensors are designed (>120% strain) with high sensitivity (gauge factor 8.47) and durability (>100,000 cycles), interconnects (>140% strain) and resistors (>250% strain), optimally arranged to form a highly stretchable sensing circuit. The wearable is knitted with a computer numerical control (CNC) knitting machine that offers a cost effective and scalable fabrication method with minimal post‐processing. The real‐time data from the wearable is transmitted wirelessly using a custom designed circuit board. In this work, an all knitted and fully integrated soft wearable is demonstrated for wireless and continuous real‐time sensing of knee joint motion of multiple subjects performing various activities of daily living. An all‐knitted knee brace with integrated electronics for wireless and continuous real‐time sensing of knee joint motion is demonstrated. It has three knitted electrical components embedded within a soft wearable to function as a stretchable circuit, each with vastly distinct electrical performance when stretched. The knee brace signal can closely follow the gold standard motion capture system.