SP-1 Project
Smart Insole Charging and Sync Case
SP-1 redesigned a large single-device smart insole charging circuit and integrated 20 charge and sync positions into 1 compact portable case.
Client
Sports technology manufacturer developing smart insole technology for in-field biomechanical analysis and professional sports performance environments.
Objective
Redesign the client’s existing smart insole charging system into a more compact, portable and scalable platform. The original charger was around A4 size and could only charge and sync 1 device at a time. The client needed a smaller, field-ready case that could charge, store and sync 20 smart insoles without increasing setup complexity for coaches, technicians or performance teams.
Challenge
Smart sports insoles are used to capture biomechanical data during training and performance environments, so the supporting hardware needed to be practical for use away from a lab or workshop.
The existing charging system was too large and limited to a single device. Scaling that design directly would have created a bulky and impractical setup, with too much hardware, cabling and handling for day-to-day use.
The new system needed to:
- charge and sync 20 smart insoles
- replace the large single-device charger with a compact multi-device platform
- keep each insole protected and organised
- support reliable USB data transfer
- reduce cable clutter
- fit into a rugged portable case
- be simple for non-engineering users to deploy and manage
Solution
SP-1 redesigned the charging and sync circuit around a compact multi-device architecture.
We developed a custom USB charging and data sync PCB, replacing the original large single-device circuit with an integrated system capable of supporting 20 smart insoles from 1 portable case. The electronics, power distribution, cable routing and internal mounting were designed together to keep the system compact, reliable and serviceable.
The case interior was arranged to protect the insoles, simplify loading and unloading, and keep the hardware organised during transport. Internal cooling and power management were built into the system to support reliable operation during repeated use.
Key features included:
- charging and data sync for 20 smart sports insoles
- redesigned charging circuit based on the original single-device charger
- custom USB charging and sync PCB
- compact multi-device electronics layout
- protected storage for each insole
- integrated power distribution
- organised internal cable routing
- bespoke PCB housing and mounting
- rugged portable case for field and training-ground use
Outcome
The finished system transformed the client’s charging workflow from a large single-device setup into a compact 20-device charge and sync case. By redesigning the electronics and integrating the hardware into 1 portable system, SP-1 reduced equipment size, improved usability and created a more practical platform for supporting smart insole deployments in professional sports and performance environments.
Project highlights
Client: Sports technology manufacturer
Application: Smart sports insole charging and data sync
System type: Portable USB charging and sync case
Device capacity: 20 smart insoles
Original system: A4-sized single-device charger
Core functions: Storage, charging, USB data sync and device protection
Electronics: Redesigned charging circuit and custom USB sync PCB
Environment: Professional sports, training and performance analysis
SP-1 role: Electronic design, PCB design, 3D design, enclosure integration, assembly and testing
