Product Development



Caltronics is developing a smart insole, a pressure-mapping platform built for proactive foot health monitoring. The insole integrates 160 embedded pressure sensors alongside a 6-axis IMU to continuously track plantar pressure distribution and motion, fitting discreetly into conventional footwear. This work builds on Caltronics’ 30+ years of experience in custom circuit board design and manufacturing.

Calsense insole prototype with embedded pressure sensor array

Calsense insole prototype – embedded pressure sensor array

Sensor data streams wirelessly over Bluetooth Low Energy (BLE) to a companion mobile app, where it is translated into real-time pressure heatmaps and risk scoring. The insole is powered by a rechargeable 3.7V Li-Ion battery rated for 10-12 hours of continuous use, with charging via USB-C or a wireless pad.

Pressure heatmap and statistics for left and right foot

Sample output from our current engineering prototype

Key Features

Bluetooth Low Energy (BLE)
Seamless wireless data streaming to mobile and desktop devices.

High-Density Pressure Sensors
160 pressure sensors per sole for high-resolution plantar pressure mapping.

6-Axis IMU
Captures acceleration and angular velocity for accurate motion tracking.

Rechargeable Battery
Long-lasting Li-Ion battery for extended use, with USB-C or wireless charging.

Real-Time Visualization
Live pressure heatmaps, center of pressure (COP) trajectory, and balance metrics.

Data Export
Export session data for further analysis and integration with other platforms.

Interested in this project or a similar one? Get in touch with our team to discuss custom sensor and circuit board manufacturing.