Fully Screen-Printed Pressure Sensing Insole—From Proof of Concept to Scalable Manufacturing

Continuous plantar-pressure monitoring is important for objective gait analysis and early detection of abnormal loading; however, many existing solutions remain laboratory-bound (force plates and instrumented walkways) or rely on costly in-shoe multilayer sensor arrays. Here, we developed and optimized a fully screen-printed pressure-sensing insole based on carbon–polymer nanocomposite layers, with an emphasis on manufacturability and process control to bridge the gap between proof-of-concept force-sensitive resistor (FSR)-based insoles and scalable printed-electronics manufacturing workflows. Composite pastes containing carbon fillers (graphene nanoplatelets, carbon black, and graphite) were formulated to improve sensor repeatability and sensitivity. Sensors were characterized under compression loads from 100 N to 1300 N, showing a sensitivity of 10.5 ± 2.8 Ω per 100 N and a sheet-to-sheet coefficient of variation of 22.1% in resistance response. The effects of paste composition, screen mesh density, electrode layout, and lamination on sensitivity and repeatability were systematically evaluated. In addition, correlation analysis of resistance values from integrated quality-control meanders proved useful for monitoring screen-printing process stability. The final insole integrates printed carbon sensing pads and contacts, a dielectric spacer, and an adhesive layer in a thin, flexible format suitable for integration with wearable electronics. In practical static-load tests, repeated manual placement of weights yielded coefficients of variation as low as 4% at 500 g and a detection limit of ~0.1 N, comparable to a very light finger touch. These results demonstrate that low-cost screen-printed electronics can provide robust pressure sensing for wearable plantar-pressure monitoring.