Frays and Whiskers

 
Conductive thread samples - Silverell, Mitsifuji, 6 ply Stainless Steel. Sparkfun
 
Short circuits in eTextiles are frequently caused by conductive thread frays and whiskers. Select your conductive thread carefully to minimize the risks.

When sewing traces that are in close proximity I use a small diameter and well plied thread such as Mitsifuji. When the traces have an inch or more space between them, as when connecting LEDs, I may choose a larger hairy thread such as the 6ply Stainless Steel with a resistance of 1 ohms/foot.