DESIGN
STUDIO
All work

03 / Selected work

Smart KAFO

Orthotic fabrication experience translated into a working wearable prototype that integrates sensing, electronics, and compact actuation with conventional orthotic hardware.

Context
Multidisciplinary capstone · 2022–2023
My role
Concept originator, team lead & fabricator
Outcome
Working bilateral walking prototype
The integrated Smart KAFO prototype: sensing, control, and compact actuation on conventional orthotic hardware.
The integrated Smart KAFO prototype: sensing, control, and compact actuation on conventional orthotic hardware.View full-size image in a new tab

Sensing

Integrating sensing into an orthotic.

I originated the concept, led the team, and performed all prototype metal fabrication. Five force sensors were integrated into a laminated foot orthotic after individual sensor and breadboard testing. A computer-engineering teammate led circuit design and most programming; we collaborated on system integration.

Sensor integration and physical fabrication of the foot orthotic.
Sensor integration and physical fabrication of the foot orthotic.View full-size image in a new tab

Integration

Actuate the lock. Preserve the joint.

Compact brackets keep the actuators close to the uprights. Dyneema cord links the actuators to the existing knee-lock levers.

Actuator packaging on conventional orthotic hardware.
Actuator packaging on conventional orthotic hardware.View full-size image in a new tab

Fabrication

Designing the system meant designing the process.

With the circuit design led by my teammate, I developed the board-fabrication process: researching the method, designing and printing two masking stencils and a drill gauge, and establishing the mask, etch, drill, populate, and solder sequence.

PCB process tooling and fabrication developed to make the team’s custom circuit physical.
PCB process tooling and fabrication developed to make the team’s custom circuit physical.View full-size image in a new tab

Demonstration

Build it. Wear it. Walk.

The final demonstration brings the fabricated orthotic, electronics, and bilateral actuators together in a wearable prototype. This excerpt shows the prototype at recorded speed.

The working wearable prototype in a walking demonstration.Download video

THE TAKEAWAY

Preserve proven mechanics. Add intelligence where it creates a useful, specific change.