Search Results (13)

Integrating bioinspired design and additive manufacturing into engineering education fosters innovation to meet the growing demand for accessible, personalized assistive technologies. This paper presents the outcomes of an international course, “3D Prosthetics and Orthotics”, offered to undergraduate students in the Biomimetic program at Westfälische Hochschule (Germany), in collaboration with the 3D Orthotics and Prosthetics Laboratory at the Federal University of São Paulo—UNIFESP (Brazil). The course combined theoretical and hands-on modules covering digital modeling (CAD), simulation (CAE), and fabrication (CAM), enabling students to develop bioinspired assistive devices through a Project-based learning approach. Working in interdisciplinary teams, students addressed real-world rehabilitation challenges by translating biological mechanisms into engineered solutions using additive manufacturing. Resulting prototypes included a hand prosthesis based on the Fin Ray effect, a modular finger prosthesis inspired by tendon–muscle antagonism, and a cervical orthosis designed based on stingray morphology. Each device was digitally modeled, mechanically analyzed, and physically fabricated using open-source and low-cost methods. This initiative illustrates how biomimetic mechanisms and design can be integrated into education to generate functional outcomes and socially impactful health technologies. Grounded in the Mao3D open-source methodology, this experience demonstrates the value of combining nature-inspired principles, digital fabrication, Design Thinking, and international collaboration to advance inclusive, low-cost innovations in assistive technology. Full article

Background: Finger orthoses are essential for treating injuries, deformities, and disorders of the upper limbs by supporting, immobilizing, or correcting deformities. Recent advances in three-dimensional (3D) printing have significantly enhanced precision and customization compared to traditional fabrication methods such as thermoplastic molding, plaster or fiberglass casting, and the use of prefabricated splints. Methods: The present review was conducted using PubMed, Scopus, and other databases with keywords such as “hand therapy”, “additive manufacturing”, “finger and thumb”, and “orthosis”. Only English-language publications were considered, with a primary focus on articles published between 2010 and 2025. Key themes were identified and categorized into conditions necessitating finger orthoses, types and classifications, ergonomic design considerations, and advancements in additive manufacturing. Results: Finger orthoses address musculoskeletal injuries, inflammatory diseases, and neuromuscular disorders. Three-dimensional printing provides enhanced customization, reduced material waste, rapid prototyping, and the ability to create complex geometries, improving patient comfort and functionality. Conclusions: Finger orthoses effectively treat various conditions by supporting and stabilizing fingers. A thorough understanding of anatomy, biomechanics, and fabrication methods is crucial for achieving functional and comfortable designs. Three-dimensional printing offers a transformative approach to producing lightweight, customizable, and cost-effective orthoses, enabling innovative and personalized solutions. By bridging clinical needs and design strategies, this review may guide future innovations in patient-specific orthotic development. Full article

Finger extension stiffness is a common post-traumatic complication that results in the hand’s functional impairment. In clinical practice, a dynamic splint enables the patient to stretch the affected finger independently. However, current dynamic splints have drawbacks, such as limited stretching efficacy, and interfere with the hand’s functional activities. Therefore, this study aimed to develop a dynamic finger flexion orthosis capable of stretching each finger joint using additive manufacturing (AM) technology, thereby enabling hand functional activity, and analyze the clinical improvement in the range of motion (ROM). One subject with a hand fracture was recruited while undergoing a 7-week home-based rehabilitation program for the orthosis. The outcome measurements included the total active motion (TAM), the tip-to-finger distance (TPD), and the score on the Disability of Arm, Shoulder, and Hand (DASH) questionnaire. The results show that the TAM of the participant’s fingers increased by 72.7 degrees on average, the TPD decreased by 3.5 cm on average, and the DASH score decreased to 9.5 points. The 7-week home-based rehabilitation program for the orthosis resulted in a 53.6% increase in the TAM on average. The developed orthosis improved hand function and enabled a more complete ROM in finger flexion. Full article

The rehabilitation process after the onset of a stroke primarily deals with assisting in regaining mobility, communication skills, swallowing function, and activities of daily living (ADLs). This entirely depends on the specific regions of the brain that have been affected by the stroke. Patients can learn how to utilize adaptive equipment, regain movement, and reduce muscle spasticity through certain repetitive exercises and therapeutic interventions. These exercises can be performed by wearing soft robotic gloves on the impaired extremity. For post-stroke rehabilitation, we have designed and characterized an interactive hand orthosis with tendon-driven finger actuation mechanisms actuated by servo motors, which consists of a fabric glove and force-sensitive resistors (FSRs) at the tip. The robotic device moves the user’s hand when operated by mobile phone to replicate normal gripping behavior. In this paper, the characterization of finger movements in response to step input commands from a mobile app was carried out for each finger at the proximal interphalangeal (PIP), distal interphalangeal (DIP), and metacarpophalangeal (MCP) joints. In general, servo motor-based hand orthoses are energy-efficient; however, they generate noise during actuation. Here, we quantified the noise generated by servo motor actuation for each finger as well as when a group of fingers is simultaneously activated. To test ADL ability, we evaluated the device’s effectiveness in holding different objects from the Action Research Arm Test (ARAT) kit. Our device, novel hand orthosis actuated by servo motors (NOHAS), was tested on ten healthy human subjects and showed an average of 90% success rate in grasping tasks. Our orthotic hand shows promise for aiding post-stroke subjects recover because of its simplicity of use, lightweight construction, and carefully designed components. Full article

Proximal interphalangeal joint flexion contracture is a frequent condition in hand therapy. Clinicians most frequently apply orthosis management for conservative treatment. Orthoses should apply forces for long periods of time following the total end range time (TERT) concept. These forces necessarily transmit through the skin; however, skin has physiological limitations determined by blood flow. Using three fresh frozen human cadavers, this study quantified and compared forces, skin contact surfaces and pressure of two finger orthoses, an elastic tension digital neoprene orthosis (ETDNO) and an LMB 501 orthosis. The study also investigated the effects of a new method of orthosis construction (serial ETDNO orthoses) that customizes forces to a specific finger position. We evaluated forces and contact surfaces for multiple ETDNO models tailored to the cadaver fingers in multiple PIP flexion positions. The results showed that the LMB 501 orthosis applied pressures beyond the recommended limits if applied for more than eight hours a day. This fact was the cause of time limited LMB orthosis application. This results also show that, at 30° of PIPJ flexion, straight ETDNOs created a mean pressure approaching the end of the recommended pressure limits. If the therapist modified the ETDNO design, the skin pressure decreased and reduced the risk of skin damage. With the results of this study, we concluded that for PIPJ flexion contracture, the upper limit of force application is 200 g (1.96 N). Forces beyond this amount would likely cause skin irritation and possibly skin injuries. This would cause a reduction in the daily TERT and limit outcomes. Full article

Focusing on fingers with proximal interphalangeal joint flexion contractures, this study seeks to determine whether significant differences exist between the joint passive range of motion PROM improvement when receiving higher doses of daily total end range time (TERT) compared to those that receive lower doses. The study randomized a parallel group of fifty-seven fingers in fifty patients with concealed allocation and assessor blinding. Divided into two groups receiving different doses of daily total end range time with an elastic tension digital neoprene orthosis, they also participated in an identical exercise program. Patients reported orthosis wear time, and the researchers performed goniometric measurements at every session during the three-week period. The primary outcome related the time patients wore the orthosis to the degrees of improvement in PROM extension. Compared to group B (daily TERT of twelve hours), group A (TERT, twenty+ hours) showed a statistically significant greater improvement in PROM after three weeks of treatment. Group A improved by a mean of 29° compared to group B’s mean of 19° improvement. This study provides evidence that a higher dose of daily TERT can generate better results in the treatment of the proximal interphalangeal joint flexion contractures. Full article

Brain–computer interfaces (BCIs) are becoming more popular in the neurological rehabilitation field, and sensorimotor rhythm (SMR) is a type of brain oscillation rhythm that can be captured and analyzed in BCIs. Previous reviews have testified to the efficacy of the BCIs, but seldom have they discussed the motor task adopted in BCIs experiments in detail, as well as whether the feedback is suitable for them. We focused on the motor tasks adopted in SMR-based BCIs, as well as the corresponding feedback, and searched articles in PubMed, Embase, Cochrane library, Web of Science, and Scopus and found 442 articles. After a series of screenings, 15 randomized controlled studies were eligible for analysis. We found motor imagery (MI) or motor attempt (MA) are common experimental paradigms in EEG-based BCIs trials. Imagining/attempting to grasp and extend the fingers is the most common, and there were multi-joint movements, including wrist, elbow, and shoulder. There were various types of feedback in MI or MA tasks for hand grasping and extension. Proprioception was used more frequently in a variety of forms. Orthosis, robot, exoskeleton, and functional electrical stimulation can assist the paretic limb movement, and visual feedback can be used as primary feedback or combined forms. However, during the recovery process, there are many bottleneck problems for hand recovery, such as flaccid paralysis or opening the fingers. In practice, we should mainly focus on patients’ difficulties, and design one or more motor tasks for patients, with the assistance of the robot, FES, or other combined feedback, to help them to complete a grasp, finger extension, thumb opposition, or other motion. Future research should focus on neurophysiological changes and functional improvements and further elaboration on the changes in neurophysiology during the recovery of motor function. Full article

In this paper, a concept for an anthropomorphic replacement hand cast with silicone with an integrated sensory feedback system is presented. In order to construct the personalized replacement hand, a 3D scan of a healthy hand was used to create a 3D-printed mold using computer-aided design (CAD). To allow for movement of the index and middle fingers, a motorized orthosis was used. Information about the applied force for grasping and the degree of flexion of the fingers is registered using two pressure sensors and one bending sensor in each movable finger. To integrate the sensors and additional cavities for increased flexibility, the fingers were cast in three parts, separately from the rest of the hand. A silicone adhesive (Silpuran 4200) was examined to combine the individual parts afterwards. For this, tests with different geometries were carried out. Furthermore, different test series for the secure integration of the sensors were performed, including measurements of the registered information of the sensors. Based on these findings, skin-toned individual fingers and a replacement hand with integrated sensors were created. Using Silpuran 4200, it was possible to integrate the needed cavities and to place the sensors securely into the hand while retaining full flexion using a motorized orthosis. The measurements during different loadings and while grasping various objects proved that it is possible to realize such a sensory feedback system in a replacement hand. As a result, it can be stated that the cost-effective realization of a personalized, anthropomorphic replacement hand with an integrated sensory feedback system is possible using 3D scanning and 3D printing. By integrating smaller sensors, the risk of damaging the sensors through movement could be decreased. Full article

(1) Background: This paper presents a conceptual design for an anthropomorphic replacement hand made of silicone that integrates a sensory feedback system. In combination with a motorized orthosis, it allows performing movements and registering information on the flexion and the pressure of the fingers. (2) Methods: To create the replacement hand, a three-dimensional (3D) scanner was used to scan the hand of the test person. With computer-aided design (CAD), a mold was created from the hand, then 3D-printed. Bending and force sensors were attached to the mold before silicone casting to implement the sensory feedback system. To achieve a functional and anthropomorphic appearance of the replacement hand, a material analysis was carried out. In two different test series, the properties of the used silicones were analyzed regarding their mechanical properties and the manufacturing process. (3) Results: Individual fingers and an entire hand with integrated sensors were realized, which demonstrated in several tests that sensory feedback in such an anthropomorphic replacement hand can be realized. Nevertheless, the choice of silicone material remains an open challenge, as there is a trade-off between the hardness of the material and the maximum mechanical force of the orthosis. (4) Conclusion: Apart from manufacturing-related issues, it is possible to cost-effectively create a personalized, anthropomorphic replacement hand, including sensory feedback, by using 3D scanning and 3D printing techniques. Full article

This paper presents the modeling design method for a novel hybrid-driven compliant hand exoskeleton based on the human-machine coupling model for the patients who have requirements on training and assisting. Firstly, the human-machine coupling model is established based on the kinematics characteristics of human fingers and the Bernoulli beam formula. On this basis, the variable stiffness flexible hinge (VSFH) is used to drive the finger extension and the cable-driven mechanism is used to implement the movement of the finger flexion. Here, a hand orthosis is designed in the proposed hand exoskeleton to act as the base and maintain the function position of the hand for patients with hand dysfunction. Then, a final design prototype is fabricated to evaluate the proposed modeling method. In the end, a series of experiments based on the prototype is proceeded to evaluate its capabilities on stretching force for extension, bio-imitability, finger flexion capability, and fingertip force. The results show that the prototype has a significant improvement in all aspects of the ability mentioned above, and has good bionics. The proposed design method can be utilized to implement the rapid design of the hybrid-driven compliant hand exoskeleton with the changed requirements. The novel modeling method can be easily applied in personalized design in rehabilitation engineering. Full article

Fused deposition modeling (FDM) is one of the most often-used technologies in additive manufacturing. Several materials are used with this technology, such as poly(lactic acid) (PLA), which is most commonly applied. The mechanical properties of 3D-printed parts depend on the process parameters. This is why, in this study, three-point bending tests were carried out to characterize the influence of build orientation, layer thickness, printing temperature and printing speed on the mechanical properties of PLA samples. Not only the process parameters may affect the mechanical properties, but heat after-treatment also has an influence on them. For this reason, additional samples were printed with optimal process parameters and characterized after pure heat treatment as well as after deformation at a temperature above the glass transition temperature, cooling with applied deformation, and subsequent recovery under heat treatment. These findings are planned to be used in a future study on finger orthoses that could either be printed according to shape or in a flat shape and afterwards heated and bent around the finger. Full article

The Hands exert a vital role in the simplest to most complex daily tasks. Losing the ability to make hand movements, which is usually caused by spinal cord injury or stroke, dramatically impacts the quality of life. In order to counteract this problem, several assisting devices have been proposed, but they still present several usage limitations. The marketable orthoses are generally either the static type or over-expensive active orthosis that cannot perform the same degrees of freedom (DoF) that a hand can do. This paper presents a conceptual design of a tendon-driven mechanism for hand’s active orthosis. This study is a part of an effort to develop an effective and low-cost hand’s orthosis for people with hand paralysis. The tendon design proposed was thought to comply with some requisitions such as lightness and low volume, as well as fit with the biomechanical constraints of the hand joints to enable a comfortable use. The mechanism employs small cursors on the phalanges to allow the tendons to run on the dorsal side and by both sides of the fingers, allowing 2 DoF for each finger, and one extra tendon enlarges the hands’ adduction nuances. With this configuration, it is simple enough to execute the flexion and extension movements, which are the most used movements in daily actives, using one single DC actuator for one DoF to reduce manufacturing costs, or with more DC actuators to enable more natural hand coordination. This system of actuation is suitable to create soft exoskeletons for hands easily embedded into 3D printed parts, which could be merged over statics thermoplastic orthosis. The final orthosis design allows dexterous finger movements and force to grasp objects and perform tasks comfortably. Full article

This study aims to present the design, selection and testing of commercial ropes (artificial tendons) used on robotic orthosis to perform the hand movements for stroke individuals over upper limb rehabilitation. It was determined the load applied in the rope would through direct measurements performed on four individuals after stroke using a bulb dynamometer. A tensile strength test was performed using eight commercial ropes in order to evaluate the maximum breaking force and select the most suitable to be used in this application. Finally, a pilot test was performed with a user of the device to ratify the effectiveness of the rope. The load on the cable was 12.38 kgf (121.4 N) in the stroke-affected hand, which is the maximum tensile force that the rope must to supports. Paragliding rope (DuPont™ Kevlar ${}^{\circledR }$ ) supporting a load of 250 N at a strain of 37 mm was selected. The clinical test proved the effectiveness of the rope, supporting the requested efforts, without presenting permanent deformation, effectively performing the participant’s finger opening. Full article