The overweight/obese individuals, in general, develop varied foot consequences during walk of life. The body weight and the prevalence of flat foot on the plantar surface are the primary indicators for the discomfort in respect of high BMI individuals. The body weight has been implicated as a factor in plantar heel [4, 11, 12]. The role of PU foam materials is of greater importance to render therapeutic advantages in footwear. The PU foam materials are widely used as varied elements in footwear and the consumers’ gain benefits and sense of satisfaction on comfort parameters. The main objective of research is to scientifically investigate the characteristics PU foam materials and explore these materials for plantar pressure analysis using In-shoe pressure measurement device on footwear designed and developed exclusively for overweight/obese individuals. The foot or thoses are commonly used in the conservative treatment of plantar fasciitis and are helpful to reduce the symptoms of strain during standing and ambulation [1,5,6,7].The investigation on PU foam materials and their efficacy as footwear inserts to provide therapeutic solutions especially for high BMI individuals has been not scientifically attempted in the domain of footwear research. Hence, the investigation on choosing ideal material thereby minimising the foot related problems being experienced by high BMI individuals is aimed at using plantar pressure analysis in this paper. The polyurethane foam materials possessing uniform substance of 4mm with varied densities such as D55, D75, D95 and D120 have been assessed on a range of physical characteristics such as Density, Hardness, Compression set followed Resiliency and cushioning behaviours. These materials are employed as foot inserts in footwear specifically designed and developed for overweight/obese individuals and the pressure analysis has been carried out using In-shoe pressure measurement method in the phase of human locomotion. Based on the results obtained on pressure analysis experiments, the ideal material aid in alleviating foot problems of high BMI individuals has been scientifically revealed and recommended to the beneficiaries.