Design a custom resistive force sensors to optimize sensorized insoles

Purpose Currently, several studies have been published using sensorized insoles for estimating ground reaction force using plantar pressure. However, information on design parameters, manufacturing techniques and guidelines for developing insoles is scarce, often leaving gaps that do not allow reproducing the insole. This study aims to empirically investigate the main parameters of constructing a sensorized insole for application in human gait. Design/methodology/approach Two devices were built to evaluate the force sensors. The first focuses on the construction of the sensors with different settings: the density of the sensor’s conductive trails (thickness and distance of the trails) and the inertia of the sensors (use of spacers to prevent unwanted readings). The second device focuses on the data capture and processing system: resolution of the analog–digital converter, acquisition rate and sensor activation level. Findings The resolution increase of the analog–digital converter and acquisition rate do not contribute to noise increase. Reducing the sensors’ coverage area can increase sensorized insole capacity. The inertia of the sensors can be adjusted using spacers without changing the electrical circuit and acquisition system. Originality/value Most sensorized insoles use commercial sensors. For this reason, it is not possible a full customization. This paper maps the main variables to manufacture custom sensors and data acquisition systems. This work also presents a case study where it is possible to see the influence of the parameters in the correlation between the sensorized insole and an instrumented treadmill with a force platform.