The sEMG is an extensive use of in prosthetic control and wearable HMI; however, the integration can be arduous as signal stability is susceptible to resistive loss, motion artifact, and deterioration arising from repetitive bending and moisture exposure over the signal path by conventional lead wires. In this study, we develop and experimentally investigate the sEMG routing in textile-integrated and prosthetic via the flexible composite transmission wires made of polymers and conductive phases. Four types of samples have been prepared to study different conduction mechanisms and mechanical response, including C-coating of AgNWs (C-AgNWs-PU), a carbon black TPU filament (C-TPU), reinforced PU blend that induces geometry self-closing in the course of curing process (C-TPEU-R) and nickel ink coated PU/TPU wire (C-Ni-TPEU). The wire-level conductance, resistance per unit length, flexibility scores, longevity in moisture and controlled parallel-routing crosstalk were measured by single method as the mean ± SD using data from 5 samples per formulations (n = 5), with mandrel-based cyclic bending for flexibility retention. Budgets on formulation were already observed: C-AgNWs-PU showed the highest conductivity (7960 ± 119 S/m) and lowest resistance (0.1172 ± 0.0037 Ω/m), although it was superior to its neighbors in flexibility (9.50 ± 0.16), and durability (9964 ± 131 cycles). The C-Ni-TPEU was highly flexible (9.10 ± 0.16) and had small resistance (0.410 ± 0.016 Ω/m) with good durability (8590 ± 96 cycles), while the carbon black TPU filament would have less conductivity and poor durability. Propagation delay per unit length was benchmarked against a clearly identified commercial baseline cable (RG-174/U 50-Ω coaxial cable) under identical length, connectorization, and termination conditions; the RG-174/U baseline exhibited an approximately 5.03 ns/m delay per meter under the stated measurement setup. Last, system-level relevance was shown by implementing the optimized wires in a textile electrode acquisition chain and testing the sEMG stability and repeatability during dynamic motion. Wearable-oriented protocols for exposure to moisture, and controlled parallel-routing crosstalk were adopted to increase replicability. In summary, the designs proposed here are a platform by which low-loss, compliant signal routing can be accomplished in sEMG and bioelectrical modalities.
