
We are excited to announce the availability of Galvorn C (“conductivity”). We have optimized this new version of Galvorn for conductivity and compatibility with standard textile manufacturing equipment.
Available today in the form of twisted yarn and fiber tow, consider Galvorn C if you’re in need of a lightweight conductor but don’t want the full strength of traditional Galvorn.
Galvorn C fibers and yarns also happen to be ~80% less than the cost of our high strength Galvorn.
Conductive yarns are used in a wide range of applications, including:
- Electrostatic discharge (ESD) protection: Fabrics that shield electronic devices from electrostatic discharge.
- Anti-static clothing: Clothing that prevents static cling and reduces the risk of sparks in hazardous environments.
- Medical devices: Electrodes for medical devices such as EKG machines and defibrillators.
- Sensors: Sensors that detect touch, pressure, and other physical properties.
- Smart textiles: Smart textiles that can interact with electronic devices and perform a variety of functions. Download our white paper: Unlocking the next generation of smart textiles with Galvorn to learn more.
In this blog post we discuss the limitations of traditional conductive yarns and why Galvorn is better. We also provide a properties comparison of Galvorn C vs. stainless steel thread.
Limitations of traditional conductive yarns (and why Galvorn is better)
Conductive yarns are essential for creating smart textiles and wearable technology. But they come with several limitations and challenges that hinder their widespread adoption and performance. Here are some of the most significant ones:
Durability
Conductive yarns can degrade with repeated washing, abrasion, or exposure to environmental conditions. The metallic components or coatings in the yarns can also be brittle and lead to fractures during weaving, knitting, or use.
One of the more durable conductive yarns on the market, stainless steel, has a strength around 500 - 800 MPa (72 - 116 ksi). Galvorn C has a strength of 800 MPa and comes with lower resistivity and lower density.
Conductivity and Performance
Conductive yarns have lower conductivity compared to solid metal wires. Yet they can still be susceptible to overheating when substantial current is passed through.
Galvorn C’s resistivity is 10 Ohms/m, about 70% better than a stainless steel thread of the same size. Watch this failure current test to see just how much current Galvorn can conduct before overheating (hint: a lot more than metal).
Compatibility with Traditional Textile Processes
Conductive yarns are often coated, or constructed with more than one material. It can make processing conductive yarns in traditional textile manufacturing equipment difficult.
Galvorn yarns behave like regular yarns: as solid, flexible carbon they feel similar to silk. But the traditional high strength yarns have at times strained commercial grade manufacturing equipment. Mills and manufacturers that use strong fibers like Kevlar will find the strength of Galvorn fibers and yarns familiar.
For the broader swath of textile producers, we hope Galvorn C makes their lives easier. Offering the ideal combination of conductivity and durability, while enabling easier knitting, weaving, and embroidery.
Material Limitations
Some conductive materials, such as silver, are prone to tarnishing or corrosion, reducing performance over time. Integrating metallic components can also make the yarn less flexible and comfortable, limiting its use in wearable applications.
Galvorn is carbon in a solid flexible form. It does not corrode or tarnish. In terms of flexibility and comfort, it feels like silk. Check out the video below showing a Galvorn fabric to get a sense of its flexibility.
Integration with Electronics
Ensuring reliable connections between conductive yarns and electronic components remains a challenge due to differences in material properties. Connect Galvorn by tying or knotting the yarn to the connector. Use multiple wraps of Galvorn to decrease the contact resistance when necessary.
Crimping is a great method for terminating Galvorn. The crimp must closely match the size of the yarn. Be sure to use only copper, tinned-copper, gold plated, or stainless steel terminals and splices.
Signal loss or noise can also occur when connecting traditional conductive yarns. This is especially true for applications requiring high-frequency or precision signals. When designing for high speed or precision measurement ensure your design accounts for impedance matching where Galvorn meets metal.
While traditional soldering with untreated Galvorn is not possible. Our customers have had success using the following methods:
- Crimp a copper ferrule of closely matched diameter and solder to that.
- Electroplate Galvorn with a copper layer, using an off the shelf copper sulfate plating kit. This is especially useful for small conductors that require a low resistance connection.
We do recommend that you provide strain-relief by anchoring the Galvorn with a knot or adhesive to prevent strain at the solder joint.
You can also braze Galvorn to a variety of substrates. Contact us for consultation regarding your specific requirements.
Environmental Impact
The production and disposal of traditional conductive yarns are causing environmental concerns. This is especially true for yarns that have metal coatings or are made from synthetic fibers.
We can sustainably produce Galvorn at scale. Compared to metals, Galvorn production requires less energy. Because it does not rely on mining, it also avoids significant land use and environmental impact.
Recent studies also validated that recycling Galvorn does not result in a loss of properties. We have known this for some time because we recycle it in our production facilities, but it is great to see the published work. Read the article or watch the video.
Biocompatibility
In wearable devices, the materials used must be safe for prolonged skin contact. Some conductive coatings or fibers may cause irritation or allergic reactions.
Galvorn is bio-compatible. In fact, today researchers use Galvorn fibers to enable targeted brain stimulation. This new approach would avoid the need for open brain surgery for patients in need of neuromodulation therapies.
Galvorn Conductive Yarn vs. Stainless Steel Thread
Stainless steel thread is one of the more common conductive yarns on the market. We offer a properties comparison below for your reference. While there is variation, depending on what grade of stainless steel yarn you use, overall Galvorn offers several advantages. Less resistance, more lightweight, and stronger.
Galvorn C | Stainless Steel Yarn | |
Resistance, ohms/m | 10 | 51 |
Density, g/cm3 | 1 | 7.9 |
Tensile Strength, GPa | 0.78 | 0.50 - 0.63 |
Tenacity (N/tex) | 0.82 | 0.15 |
Diameter, µm | 200 | 200 |
If you’re interested in trying Galvorn C for yourself, you can purchase samples from our online store. Please also feel free to contact us if you would like to discuss your application and determine if Galvorn C is a good fit.