Low-Cost Spray-Patterned Triboelectric Textiles for Wearable Interaction and Energy Harvesting

Smart textile interfaces hold promise for battery-free wearable interaction, yet their adoption is limited by complex fabrication and insufficient on-body evaluation. We present TriboTex, a low-cost spray-patterning workflow that forms nylon-Cu-nylon triboelectric stacks on cotton textiles using laser-cut PET stencils and commercially available materials. The core consumables cost approximately USD 0.003/cm², and sensor geometry can be rapidly iterated by modifying only the digital stencil. Controlled characterization across nine devices from three fabrication batches showed a peak open-circuit voltage of 52.3 V and a maximum power density of 1870 µW/m² at 4 GΩ. The output retained 96.1% of its initial voltage after 1000 bending cycles and 94.2% after 24 h of simplified saline immersion. Three-sample environmental sweeps showed voltage amplitudes of 41.9-43.7 V from 15 to 45 °C, with a decrease to 27.7 V at 0 °C; the humidity response remained within 92.7-104.5% of the 20% RH value over 20-60% RH but decreased to 19.9% at 70% RH. Two wearable prototypes were developed: a single-electrode garment sleeve recognized tap, double-tap, and swipe gestures with 95.0% accuracy across 1200 trials from 12 participants; a single-electrode insole generated action-dependent peak voltages up to 123 V under repeated foot loading and was connected through a rectification and voltage-regulation module to charge a battery. Across the two 12-participant studies, attachment and fit stability emerged as shared integration requirements, while participant feedback and controlled humidity measurements highlighted moisture management as a priority for reliable on-body sensing and energy capture. The primary contribution is an accessible, low-cost, and geometry-flexible route for early-stage wearable sensing experiments and application demonstrations, supported by documented fabrication, electrical characterization, and human-centered evaluation.