Spring loaded knee brace (aka knee exoskeleton) is a medical device designed to support Knees and help to relieve pain in chronic conditions like arthritis. The device operates by storing the potential energy in a spring and converting it into kinetic energy to assist movement. This design case study focuses on addressing a key limitation identified in my research on existing knee brace solutions.

Problem Statement:

Most knee braces offer a fixed level of assistance that cannot be adjusted in real time, often compromising knee mobility which can limit user comfort, adaptability, and mobility. Based on the activity engaged in, a user might need extra assistance or reduced assistance from the knee brace.

Exploration & Ideation:

I began with brainstorming and hand-drawn sketches to explore different mechanical approaches for adjustable assistance. This step allowed me to quickly test ideas, visualize form, and assess whether the concepts aligned with the core problem. The sketches served as a foundation for understanding both the product’s functionality and its physical design.

Design Development:

The entire design was developed from the concept phase and iteratively refined to meet both functional and user-centered goals, with a strong focus on functionality, aesthetics, comfort, and ease of use.

The final solution integrates a unique mechanism that gives users direct control over spring-assisted force via a side-mounted controller and preserves the full range of motion of the knee brace.

Final Solution:

The integrated mechanism allows on-the-go customization of assistance without interrupting use—users can now increase assistance while seated without compromising the knee mobility.