Durability of Wearable Buckle and Snap Magnetic Connectors—Impact of Mating/Unmating Cycles, Mating Force, and Interconnect Methods

The advent of wearable electronic textiles (e-textiles) is transforming human–computer interaction by enabling seamless, comfortable, and continuous connectivity between users and digital systems. Although the wearable e-textile market is poised for significant growth, there is a need for durable, reliable connectors to link e-textiles to digital systems. This study presents and evaluates two novel magnetic connectors—buckle and snap—integrated into textile substrates using conductive epoxy, conductive stitches, and solder as interconnect methods. Durability testing involved 5000 mating/unmating cycles at low, medium, and high forces, with electrical performance assessed through resistance and impedance measurements. Results showed significant increases in resistance and impedance with 1000-cycle intervals. However, both connectors retained robust electrical and mechanical integrity, with all resistance values remaining below 1.6 Ω, indicating no critical degradation. Buckle connectors consistently outperformed snap connectors, which is attributed to their design that reduces mechanical stress on interconnects. Conductive epoxy demonstrated superior stability and slower degradation compared to conductive stitches and solder, particularly under higher mating forces. Impedance results mirrored resistance trends, confirming reliability. These findings advance durable, user-friendly connectors for long-term e-textile use, addressing both mechanical endurance and electrical performance to enhance wearable computing and interactive environments.