{"status":"ok","message-type":"work","message-version":"1.0.0","message":{"indexed":{"date-parts":[[2026,2,26]],"date-time":"2026-02-26T12:10:01Z","timestamp":1772107801880,"version":"3.50.1"},"reference-count":24,"publisher":"MDPI AG","issue":"5","license":[{"start":{"date-parts":[[2026,2,26]],"date-time":"2026-02-26T00:00:00Z","timestamp":1772064000000},"content-version":"vor","delay-in-days":0,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0\/"}],"funder":[{"DOI":"10.13039\/501100005632","name":"National Centre for Research and Development (NCBR) project: Functional composite materials for printable sensors in telerehabilitation\u2014EUKINES","doi-asserted-by":"publisher","award":["TECHMATSTRATEG-III\/0032\/2019"],"award-info":[{"award-number":["TECHMATSTRATEG-III\/0032\/2019"]}],"id":[{"id":"10.13039\/501100005632","id-type":"DOI","asserted-by":"publisher"}]}],"content-domain":{"domain":[],"crossmark-restriction":false},"short-container-title":["Sensors"],"abstract":"<jats:p>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\u2013polymer 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 \u00b1 2.8 \u03a9 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.<\/jats:p>","DOI":"10.3390\/s26051456","type":"journal-article","created":{"date-parts":[[2026,2,26]],"date-time":"2026-02-26T11:23:45Z","timestamp":1772105025000},"page":"1456","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":0,"title":["Fully Screen-Printed Pressure Sensing Insole\u2014From Proof of Concept to Scalable Manufacturing"],"prefix":"10.3390","volume":"26","author":[{"ORCID":"https:\/\/orcid.org\/0000-0002-6533-8163","authenticated-orcid":false,"given":"Piotr","family":"Walter","sequence":"first","affiliation":[{"name":"Printed Electronics, Textronics & Assembly Lab, Centre for Advanced Materials and Technologies CEZAMAT, Warsaw University of Technology, 19 Poleczki, 02-822 Warsaw, Poland"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"ORCID":"https:\/\/orcid.org\/0000-0001-8760-2669","authenticated-orcid":false,"given":"Andrzej","family":"Pep\u0142owski","sequence":"additional","affiliation":[{"name":"Printed Electronics, Textronics & Assembly Lab, Centre for Advanced Materials and Technologies CEZAMAT, Warsaw University of Technology, 19 Poleczki, 02-822 Warsaw, Poland"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"ORCID":"https:\/\/orcid.org\/0000-0001-9246-781X","authenticated-orcid":false,"given":"Filip","family":"Budny","sequence":"additional","affiliation":[{"name":"Printed Electronics, Textronics & Assembly Lab, Centre for Advanced Materials and Technologies CEZAMAT, Warsaw University of Technology, 19 Poleczki, 02-822 Warsaw, Poland"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"ORCID":"https:\/\/orcid.org\/0000-0001-5465-2985","authenticated-orcid":false,"given":"Sandra","family":"Lepak-Kuc","sequence":"additional","affiliation":[{"name":"Printed Electronics, Textronics & Assembly Lab, Centre for Advanced Materials and Technologies CEZAMAT, Warsaw University of Technology, 19 Poleczki, 02-822 Warsaw, Poland"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-9115-9994","authenticated-orcid":false,"given":"Jerzy","family":"Sza\u0142apak","sequence":"additional","affiliation":[{"name":"Institute of Mechanics and Printing, Faculty of Mechanical and Industrial Technology, Warsaw University of Technology, 85 Narbutta, 02-524 Warsaw, Poland"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"ORCID":"https:\/\/orcid.org\/0000-0001-7192-6642","authenticated-orcid":false,"given":"Tomasz","family":"Raczy\u0144ski","sequence":"additional","affiliation":[{"name":"Printed Electronics, Textronics & Assembly Lab, Centre for Advanced Materials and Technologies CEZAMAT, Warsaw University of Technology, 19 Poleczki, 02-822 Warsaw, Poland"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"ORCID":"https:\/\/orcid.org\/0009-0005-9034-138X","authenticated-orcid":false,"given":"Mateusz","family":"Korona","sequence":"additional","affiliation":[{"name":"Institute of Mechanics and Printing, Faculty of Mechanical and Industrial Technology, Warsaw University of Technology, 85 Narbutta, 02-524 Warsaw, Poland"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"ORCID":"https:\/\/orcid.org\/0009-0001-8967-1737","authenticated-orcid":false,"given":"Zeeshan","family":"Zulfiqar","sequence":"additional","affiliation":[{"name":"Clinic of Rehabilitation and Orthopedics, Department of Rehabilitation and Physiotherapy, Medical University of Lublin, Jaczewskiego 8, 20-090 Lublin, Poland"},{"name":"College of Medicine, Gulf Medical University, Ajman P.O. Box 4184, United Arab Emirates"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"ORCID":"https:\/\/orcid.org\/0000-0003-3282-7486","authenticated-orcid":false,"given":"Andrzej","family":"Kotela","sequence":"additional","affiliation":[{"name":"Faculty of Medicine, Collegium Medicum, Cardinal Stefan Wyszynski University in Warsaw, W\u00f3ycickiego 1\/3, 01-938 Warsaw, Poland"}],"role":[{"role":"author","vocabulary":"crossref"}]},{"ORCID":"https:\/\/orcid.org\/0000-0002-9549-0385","authenticated-orcid":false,"given":"Ma\u0142gorzata","family":"Jakubowska","sequence":"additional","affiliation":[{"name":"Printed Electronics, Textronics & Assembly Lab, Centre for Advanced Materials and Technologies CEZAMAT, Warsaw University of Technology, 19 Poleczki, 02-822 Warsaw, Poland"},{"name":"Institute of Mechanics and Printing, Faculty of Mechanical and Industrial Technology, Warsaw University of Technology, 85 Narbutta, 02-524 Warsaw, Poland"}],"role":[{"role":"author","vocabulary":"crossref"}]}],"member":"1968","published-online":{"date-parts":[[2026,2,26]]},"reference":[{"key":"ref_1","doi-asserted-by":"crossref","unstructured":"Legrand, M., Grenet, F., Hochstrasser, O., Luft, A., Gassert, R., Lambercy, O., and Easthope Awai, C. 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