Objectives

PHYS-EX was conceived to contribute to the evolution of the Textiles, Fashion and Accessories sector by developing a smart sports garment that combines technological innovation, environmental sustainability and a concrete focus on the end user.

In particular, the project aims to:

• develop smart sports shirts equipped with integrated sensor modules;
• design lightweight, durable internal components compatible with sports use;
• test the use of eco-friendly materials and 3D-printed solutions;
• facilitate disassembly, maintenance and selective recycling of electronic components;
• reduce waste, integration defects and premature obsolescence of technical garments;
• create a replicable demonstrator platform for future smart clothing lines;
• strengthen collaboration among technology companies, creative businesses, digital specialists and operators in Lombardy’s fashion-tech supply chain.

The project goes beyond creating a technology-enabled shirt, experimenting with a new relationship between the physical product and the digital service, in which the garment can collect data, interact with a software platform, be updated over time and retain value throughout its entire life cycle.

Techinnova’s contribution

PHYS-EX is based on developing a new generation of smart sportswear designed for use in real sports settings without compromising comfort, freedom of movement or athletic performance.

The project begins with an analysis of usage conditions across the sports considered: exertion intensity, session duration, perspiration, areas of friction, fabric deformation, pressure points, and freedom of movement of the chest and shoulders. This information guides the design of the sensor architecture, insertion geometries and interface areas between the electronic components and the textile garment.

Techinnova’s contribution focuses in particular on the design of sensor modules and the form factor of the PHYS-EX shirts. The activity includes the use of the patented eco-friendly resin (EP4255984) to create, through 3D printing, internal microstructures such as protective housings for sensors, flexible wiring channels, low-density stabilising inserts and supports designed to withstand bending, tensile stress and intensive use.

Front view of the hardware module: (a) MAX30100 sensor for blood oxygen saturation, (b) LCD module, (c) battery level indicator, (d) power button and LED, (e) magnets for the attachment mechanism.

The design takes into account the need to make the internal modules disassemblable, replaceable and selectively recyclable. This approach reduces non-recoverable end-of-life waste and makes PHYS-EX consistent with the principles of eco-design, repairability and circularity.

Rear view of the module: (f) MLX90614 body-temperature sensor, (g) air inlet for the BME280 environmental sensor.

To validate the solutions developed, Techinnova carries out pre-functional bench tests simulating torsion, cyclic tensile loads and localised compression typical of the sports considered (cycling, running, football and fit box). The tests assess sensor-signal stability, material resistance, adhesion of components to the fabric, the behaviour of 3D supports and local temperature control near the electronic modules.

Pre-functional testing of the PHYS-EX smart garment to verify signal stability,
material resistance and technical parameters.

Results

PHYS-EX supports the growth of a more innovative, sustainable and competitive regional supply chain by testing a smart technical garment designed to last longer, generate less waste and open new development opportunities for connected sportswear.

With regard to Techinnova’s activities, the main results include:

• the definition of the sensor architecture for the PHYS-EX shirts;
• the design of the new form factor of the smart garments;
• the experimental use of the patented eco-friendly resin (EP4255984) for 3D-printed internal components;
• the creation of functional prototypes differentiated by sport and intensity of use;
• the preliminary validation of protective housings, channels, stabilising inserts and 3D supports;
• the definition of guidelines for sensor positioning, housing thickness and the configuration of internal supports;
• the production of technical data sheets covering materials, sensor layout, assembly methods and end-of-life instructions;
• the preparation of a validated form-factor specification to support subsequent firmware, system-integration and volunteer-testing activities.

Overall, the project aims to produce a replicable demonstrator platform for other lines of technical apparel, guidelines for integrating electronics and innovative materials while minimising environmental impact, and a stable collaboration model among Lombardy’s creative, digital and manufacturing businesses.

Partnership

The PHYS-EX project is developed by a partnership comprising SNJ Media Studio S.r.l., Techinnova S.p.A., MTM S.r.l. and TUTTOTONDO S.r.l., bringing together complementary expertise in software, research and development, materials, technology integration, communication, behavioural design and regional testing.

SNJ Media Studio S.r.l. – Lead Partner
SNJ Media Studio coordinates the development of the advanced firmware and the Physical AI Platform. Its activities cover real-time processing of multisensor data, energy-consumption optimisation, management of sensor protocols, development of Physical AI and Behavioral AI models, creation of an API layer for external developers, and integration of secure consent, data-flow and authorisation systems in line with GDPR and data-minimisation principles.

Techinnova S.p.A. – Partner Company
Techinnova is responsible for designing the sensor modules and the form factor of the smart shirts. The company works on integrating electronic components into the textile garment, using patented eco-friendly resin (EP4255984), producing 3D-printed internal microstructures, and carrying out preliminary validation through torsion, tensile, compression and signal-stability tests.

MTM S.r.l. – Partner Company
MTM is responsible for system integration and technical validation of the PHYS-EX prototypes. Activities include integration of hardware, firmware and the Physical AI platform; definition of wiring layouts and attachment points; setup of a pilot assembly line; quality controls; electrical and mechanical tests; interoperability testing; and field validation with selected teams and athletes.

TUTTOTONDO S.r.l. – Partner Company
TUTTOTONDO coordinates athlete engagement, behavioural nudging and participatory testing activities in collaboration with Università Cattolica. Its role includes designing engagement protocols, mapping use contexts, defining motivational micro-messages and micro-interventions, collecting qualitative feedback, involving teams, sports groups and volunteers, and producing guidelines to transfer the experience to other sports or educational settings.

WITH THE SUPPORT OF