The smart insole consists of electronic sensors and a thermoplastic insole structure. The production process has three main phases including :
Foot Scanning
Insole Modeling & Sensor Layout / Design
Printing / Electronics Enclosure

Roy begins by scanning a model of the foot which will be used for modeling the insole. Using the visualized scan data in the modelling software, he can easily locate the correct position on the insole by aligning the insole shape with the model of the feet. Roy’s design places two pressure sensors in the position of the heel and the second metatarsal. Bluetooth modules are also installed in the arch area.
By using a visual model and 3D printing, Roy can maximize the protection of enclosed electronics by designing an appropriate space layout and controlling the hardness of the insole with filament selection and infill rate. All components will be enclosed between layers of filament.