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A cyclist wearing an EL cycling jacket in the nighttime
Case study

Platilon® TPU Films drive electroluminescence (EL) solutions for enhanced safety

The integration of Platilon® TPU films as a flexible carrier for printed electronics and stretchable lighting into fabric laminates and textiles helps develop safety-enhancing solutions for a wide range of applications. Discover XTRA Dynamics’ EL Cycling Jacket where design meets safety and functionality.
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Task

Integrating flexible TPU films in fabrics to outperform conventional lighting technologies

In low-light outdoor conditions, like dusk, night, rain, or fog, people wearing conventional clothing and apparel are often hard to see. Conventional clothing only reflects light when hit directly, making visibility poor without direct illumination. This creates serious risks for pedestrians, cyclists and riders. Improved self-illuminating clothing and high-visibility gear are essential for commuter safety and outdoor visibility.

Challenge

Developing the world’s first luminous jacket with X-TENSE stretchable light technology

Cyclists, riders and walkers are hardest to see from the side. Usually on the side of a bike, reflectors are only visible when illuminated by an external light source. Until now, most safety clothing technology relied on LEDs and OLEDs. Safety through active lighting, however, is vital not only for leisure and sporting activities, but also for a wide range of other applications, for example emergency services, rescue operations, firefighting and construction – where enhanced side visibility can save lives. 

To address this, Covestro and XTRA Dynamics have joined forces in a pioneering collaboration that has resulted in the development of X-TENSE - the world’s first stretchable, paper-thin, impact-resistant, and washable light source. Using Covestro’s advanced flexible thermoplastic polyurethane (TPU) films for printed electronics, X-TENSE enables seamlessly integrated, customizable lighting in smart technical textiles and apparel across sportswear, mobility, safety gear, and workwear.

The key challenge was to come up with a stretchable luminous film for printed electronics that also serves as a durable, protective laminate and integrates seamlessly into textiles. This led to the creation of the nulumo commuter01, the world’s first jacket with X-TENSE stretchable light. X-TENSE and Platilon® TPU Film enable luminous fabrics that maintain brightness, stretchability, and washability for excellent safety in low-light conditions - setting a new standard in wearable safety technology.

“XTRA Dynamics develops electroluminescent films and matching electronics for textile integration. The stretchable, thin, and washable X-TENSE film enables new possibilities, allowing seamless integration into textiles like workwear, government uniforms, and functional clothing.’’

Matthias Krämer

Founder, XTRA Dynamics

Solution

Protective lamination for active lighting technology

With a thickness of about 100 micrometers on a stiff PP carrier, Platilon® Film provides the protective lamination for X-TENSE, a flexible, paper-thin, highly stretchable, and impact-resistant illuminated film that can be integrated into textile surfaces with up to 20% stretchability. 

A precise screen-printing process supported by the flexible Platilon® TPU Film, illuminated areas and conductive tracks can be seamlessly integrated into the film. The TPU film technology developed by XTRA Dynamics is extremely thin (less than 200 micrometers) and has a service life of approximately 20,000 hours. 

Thanks to the excellent properties of Platilon® TPU Films and EL solutions, they serve as a versatile foundation for flexible lighting applications across textile, automotive, and other consumer-focused markets. Whether in sportswear, safety gear or workwear, these films enable energy-efficient, lightweight, and long-lasting lighting solutions that enhance visibility, safety, and design freedom in low-light environments.

“Our flexible, high-performance thermoplastic polyurethane (TPU) Platilon® Film is perfectly designed as carrier material for printed electronics technologies and for integration into textile and fabric laminates. It ensures reliable processability for our customers in combination with adjustable properties towards the end-use application.” 

Dirk Pophusen

Global Segment Manager, Consumer & Industrial Solutions, Specialty Films, Covestro

Key benefits

  • Improved visibility: Active illumination for enhanced safety and visibility in low-light conditions.
  • Comfort: Seamless textile integration, lightweight and breathable for comfortable wear.
  • Durable protection: A reliable substrate for printed electronics, Platilon® Films ensure durability.
  • Ultra-thin: Platilon® TPU Films combine durability with adaptability for flexible movement.
  • Weather-resistant: Excellent moisture protection, ideal for all-weather and humid environments.
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Safety-enhancing illumination with Platilon®

Explore how protective lamination aids active illumination in printed electronics for enhanced safety

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