Team Members
What we did
Accurate assessment of motor recovery in stroke patients often requires consistent and stable arm positioning during gameplay-based evaluation tasks. Current setups may lack sufficient support or require manual assistance, introducing variability and limiting ease of use.
Reliable motor function evaluation is essential for tracking recovery progress and guiding clinical decisions. A hands-free, standardized support system can improve data quality and make testing more accessible in clinical and lab settings.
We designed a 3D-printed, ambidextrous brace system that comfortably stabilizes the user’s arm during testing. The brace integrates two internal airbags and a blood pressure cuff to provide gentle push support, while a moulded guide indicates proper hand placement. The brace is mounted on a custom stand and placed on a height-adjustable lab desk, allowing ergonomic use without human assistance.
Prototyping Process
Our design process began with the goal of creating a flexible brace that could adapt to different arm sizes. We initially proposed a two-part design connected by an elastic strap to accommodate a variety of forearm widths. The first prototype was constructed using a paper cylinder and tape to test the concept quickly and inexpensively.
In the second iteration, we focused on finding a biocompatible, easily cleanable, and moldable material. Although we initially considered 3D printing, we were advised that it would be hard to iterate quickly. Instead, we used thermoform foam, which we softened in hot water and molded around the arm to shape the brace. Early molding attempts were challenging due to uncertain sizing and the need for ambidextrous usability, but we eventually achieved a stable and usable form.
To improve comfort and internal support, we experimented with integrating an airbag. Our first test used a random air bladder found in the Design Lab, along with a basic inflation/deflation valve. To improve reliability and control, we later repurposed an air system from a working boot we purchased online. This new bladder could be inflated or deflated from either side of the brace, offering greater convenience.
Once the general structure and comfort features were validated, we transitioned to SolidWorks modeling and 3D printing to formalize the shape. To eliminate the need for a second person to hold the brace in place, we developed a custom stand, inspired by the base of a wine bottle holder, to stabilize the brace during use. For adjustability and ergonomic flexibility, we mounted the system on a height-adjustable lab desk, completing our integrated setup.
Lessons Learned
Throughout the development of our stroke rehabilitation brace, we gained valuable insights into both technical and managerial aspects of medical device design. The iterative design approach proved essential; frequent prototyping coupled with user feedback allowed us to refine our device effectively, significantly improving functionality, comfort, and usability. We recognized early on that thoughtful material selection was crucial, impacting comfort, structural integrity, aesthetics, and hygiene. Moreover, the importance of clear team communication and structured project management was shown, enabling efficient task completion. Engaging directly with customers also clarified their true needs and expectations, leading to a more relevant, user-centered design approach. These experiences collectively strengthened our skills and informed our development as design engineers.