A Garment-based Physiological Monitoring System for High- Performance Environments

Physiological monitoring is essential for early detection of health anomalies and continuous performance assessment, particularly in high-demand operational settings such as defense and aerospace. However, conventional wearable systems are often limited by rigid electronics, poor skin conformity, and signal degradation during movement - factors that compromise long-term reliability and usability. This study introduces TacMON, a textile-based physiological monitoring garment and next-generation compression eGarment platform. TacMON employs a novel Soft Electronics Assembly method to embed conductive pathways directly into stretchable textiles, enabling seamless biosignal acquisition with enhanced flexibility, durability, and wearer comfort. TacMON’s performance was validated through the development of PHYSIO, an aircrew physiological monitoring solution fabricated from flame-retardant materials and tested in U.S. Air Force cockpit environments. Human subject trials confirmed reliable ECG and respiratory signal acquisition under dynamic and in-flight conditions, demonstrating stable signal fidelity and robust system performance.