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

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.

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.

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.