Measuring the foot plantar pressure has the potential to be an important tool in many areas such as enhancing sports performance, diagnosing diseases, and rehabilitation. In general, the plantar pressure sensor should have robustness, durability, and high repeatability, as it should measure the pressure due to body weight. Here, we present a novel insole foot plantar pressure sensor using a highly sensitive crack-based strain sensor. The sensor is made of elastomer, stainless steel, a crack-based sensor, and a 3D-printed frame. Insoles are made of elastomer with Shore A 40, which is used as part of the sensor, to distribute the load to the sensor. The 3D-printed frame and stainless steel prevent breakage of the crack-based sensor and enable elastic behavior. The sensor response is highly repeatable and shows excellent durability even after 20,000 cycles. We show that the insole pressure sensor can be used as a real-time monitoring system using the pressure visualization program.

Among many flexible mechanosensors, a crack-based sensor inspired by a spider’s slit organ has received considerable attention due to its great sensitivity compared to previous strain sensors. The sensor’s limitation, however, lies on its vulnerability to stress concentration and the metal layers’ delamination. To address this issue of vulnerability, we used fluorinated ethylene propylene (FEP) as an encapsulation layer on both sides of the sensor. The excellent waterproof and chemical resistance capability of FEP may effectively protect the sensor from damage in water and chemicals while improving the durability against friction.