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    Sports wearable development

    From racket sensors to smart insoles: we design the electronics, firmware, apps and mechanics that turn motion into insight — and take them to certified production.

    Wearables are the hardest corner of IoT: meaningful motion data from a device small enough to forget you are wearing it, on a battery that lasts, in an enclosure that survives sweat, impact and the occasional washing machine. Most products in this space die somewhere between a working demo and hardware that athletes trust every week.

    We have built through that gap. PadelPlay puts real-time swing analytics on a padel racket over Bluetooth LE, and JOGO tracks football training from an in-shoe sensor platform. One team covers sensor hardware, firmware, the app, and the cloud, so the data pipeline is designed as a whole rather than stitched together across vendors.

    What we build

    Motion sensing & analytics

    IMU selection, sensor fusion, and on-device processing that turn raw accelerometer and gyroscope data into swings, steps, hits, and technique metrics users actually act on.

    Bluetooth LE & companion apps

    Production-hardened BLE firmware with OTA updates, paired with mobile apps that sync sessions reliably in real sports conditions, not just on the lab bench.

    Ultra-low-power electronics

    Power budgets engineered from day one, with duty-cycle modelling, aggressive sleep states, the right radio strategy, and measured current on prototype hardware. Battery size and charging strategy follow the actual use case.

    Wearable-grade mechanics

    Miniaturised PCBs and enclosures designed around the body: impact and moisture resistance, required ingress protection, comfort, and production-tooling readiness.

    PadelPlay smart padel racket with integrated swing sensor
    PadelPlay
    JOGO in-shoe sensor platform for football training analytics
    JOGO

    How a wearable project runs

    1

    Use case & requirements

    We define what the wearable must sense, how accurately, and for how long on a charge, and what the athlete or user should see in the app.

    2

    Prototype hardware & firmware

    A working sensor node with live data streaming, built on low-power platforms such as Nordic nRF52/53, so sensing, connectivity, and power behaviour can be validated early.

    3

    Field testing & data validation

    Real sessions with real users. We compare sensor output against appropriate ground truth and iterate the algorithms until the metrics are reliable enough for the intended use.

    4

    DFM & certification

    Design-for-manufacturing review, pre-compliance checks, and coordination of the applicable CE/RED and FCC requirements before the product moves into production.

    5

    Production & scaling

    Pilot runs to volume production with custom test fixtures and yield tracking via Insyght Console, managed by our engineer on site in Shenzhen.

    Frequently asked questions

    Can we make a very small wearable with long battery life?

    We assess the whole system: battery, antenna, electronics, enclosure and how it is worn. First define the required measurements, update frequency and charging opportunities. Then measure energy consumption under representative conditions. Size, runtime, performance and cost influence one another, so we distinguish essential requirements from preferences.

    Have you built sports wearables before?

    Yes. PadelPlay is a smart padel racket sensor with real-time swing analytics over Bluetooth LE and a companion app, and JOGO is an in-shoe sensor platform for football training analytics. Both were built by our team covering electronics, firmware, app and cloud.

    How do you get acceptable battery life in something so small?

    By treating the power budget as a first-class requirement from day one: duty-cycle modelling before schematic capture, aggressive sleep states, the right radio strategy, and measured rather than estimated currents on prototype hardware.

    Can you handle the mobile app and data platform too?

    Yes. We can design sensor processing on the device, the BLE protocol, the mobile app, and the cloud backend together, so session data moves reliably through the system and the app metrics stay tied to what the sensor actually measured.

    What does a wearable project cost and how is it structured?

    Every programme is broken into stages with defined milestones: feasibility, prototype, field validation, DFM and certification, then production. Each stage is quoted separately, so you commit incrementally and always know the next decision point.

    Do you take care of certification?

    Yes. We consider compliance from the early PCB revisions, run pre-compliance checks, and coordinate the applicable CE/RED and FCC testing with our accredited lab partner.

    Building a smart padel racket with sensors, an app, and AI feedback sounds straightforward… until you actually try to do it. Insyght took care of everything: the electronics, integrating it into the racket, the firmware, and the app. One team and full ownership. And honestly, just great people to work with.

    Manuel Benavente Roldán
    Manuel Benavente RoldánDirector at PadelPlay
    Read the case study

    Building a sports wearable?

    Talk to the team that shipped PadelPlay and JOGO — a free 30-minute consult on your sensor, battery and data questions.