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This paper aims to present the details of isotactic polypropylene (it-PP) films with a cellular structure (air-cavities) dedicated to pressure sensors. The polymer composites (thin films enriched with 5 and 10 wt% of mineral fillers as Sillikolloid P 87 and glass beads) should exhibit suitable structural elasticity within specific stress ranges. After the deformation force is removed, the sensor material must completely restore its original shape and size.

Estimating the stiffness tensor element (C₃₃) for polymer films (nonpolar space-charge electrets) by broadband resonance ultrasound spectroscopy is a relatively simple method of determining the safe stress range generated in thin pressure sensors. Therefore, ultrasonic and piezoelectric studies were carried out on four composite it-PP films. First, the longitudinal velocity (v_L) of ultrasonic waves passing through the it-PP film in the z-direction (thickness) was evaluated from the ω-position of mechanical resonance of the so-called insertion loss function. In turn, the d₃₃ coefficient was calculated from accumulated piezoelectric charge density response to mechanical stress.

Research is at an early stage; however, it can be seen that the mechanical orientation of the it-PP film improves its piezoelectric properties. Moreover, the three-year electric charge stability of the it-PP film seems promising.

Ultrasonic spectroscopy can be successfully handled as a validation method in the small-lot production of polymer films with the air-cavities structure intended for pressure sensors. The structural repeatability of polymer films is strongly related to a homogeneous distribution of the electric charge on the electret surface.

This paper aims to present a prototype of the diagnostic system for the examination of the distribution of the force applied by foot to substrate during usual human moving. Presented system is competitive to other currently available devices, thanks to sensors reliability, user-friendly operation manner and design based on cheap parts. The results of examinations are transmitted by radiomodem. Its recording and visualization are possible on either personal or mobile computers.

During selection of the sensors substrate, many polymeric electrets were examined. Polyvinylidene fluoride films were selected, because they have good charge uniformity across the surface, wide range of acceptable temperatures, linear relation between mechanical stress and output signal and high resistance for squeezing. The system measures the charge generated in film.

The pressures are recorded in relation to maximum value; therefore, measuring system does not require calibration. The simultaneous recording of data from all eight sensors allows tracking the signal without distortion.

An array of sensors is installed in the shoe insole. The measuring device is fixed to the outer surface of the shoe. Its weight is 75 g. The range of transmission is suitable for examination in the natural environment, outside traditional consulting room. Software is dedicated for analysis of the pressure distribution in every moment of the foot movement. The system is suitable for examination of flat feet, diabetic foot and recovery progress after injures.