Wearable sensor systems will soon become part of the available medical tools for remote and long term physiological monitoring. However, the set of variables involved in the performance of these systems are usually antagonistic, and therefore the design of usable wearable systems in real clinical applications entails a number of challenges that have to be addressed first. This paper describes a method to optimise the design of these systems for the specific application of cardiac monitoring. The method proposed is based on the selection of a subset of 5 design variables, sensor contact, location, and rotation, signal correlation, and patient comfort, and 2 objective functions, functionality and wearability. These variables are optimised using linear and nonlinear models to maximise those objective functions simultaneously. The methodology described and the results achieved demonstrate that it is possible to find an optimal solution and therefore overcome most of the design barriers that prevent wearable sensor systems from being used in normal clinical practice.