Design and validation of a modular smart headband with embroidered electrodes for comfortable EEG monitoring

BACKGROUND: Wearable electroencephalography (EEG) systems enable neural monitoring beyond controlled laboratory environments. However, conventional EEG devices are limited by bulky hardware, lengthy setup procedures, electrode-related discomfort or irritation, and high costs, restricting their suitability for long-term real-world use. OBJECTIVE: This study presents the design and validation of a modular smart EEG headband integrated with soft e-textile electrodes for comfortable, reliable out-of-lab EEG acquisition suitable for long-term neural monitoring. METHODS: This research developed six adjustable, replaceable embroidered electrodes (textrodes) incorporating a foam layer to improve scalp contact. These textrodes were embedded in a neoprene headband and positioned over the frontal and temporal regions just below the hairline. The performance of the smart headband in detecting spectral and event-related potential (ERP) effects in three standard tasks, such as eyes open/closed, auditory oddball, and visual oddball, on ten healthy participants, was validated and compared with a commercial system endowed with sponge-based wet electrodes. Comfort and usability were assessed via a standardized questionnaire. RESULTS: The smart headband reliably captured alpha-band modulation during the eyes open/closed task (p = 0.01) and significant ERP effects in both the auditory and visual oddball tasks (p = 0.014 and p = 0.013, respectively), demonstrating performance comparable to the commercial system. Questionnaire results indicated superior comfort and the elimination of skin irritation for the smart headband. CONCLUSION: The smart headband demonstrates detectability of spectral/ERP functional responses comparable to a commercial sponge-based EEG cap, while substantially improving user comfort. SIGNIFICANCE: By combining soft embroidered electrodes with a wearable, modular form factor, this study advances wearable EEG technology toward comfortable, cost-effective applications, aligning with emerging needs in real-world neuromonitoring.