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Developing a Low-Cost Wearable Exosuit for Rehabilitation

by yass_omr

Hi everyone! My name is Yassir, and I am an engineering student at the University of Southern Denmark (SDU). I am incredibly excited to share my current project with the DesignSpark community: designing and developing a Low-Cost Wearable Exosuit for Assisted Mobility and Rehabilitation

As global populations age, mobility deficits and the risk of falls are significantly increasing. One of the most fundamental daily activities that becomes difficult for elderly individuals or post-injury patients is the sit-to-stand (STS) transition.

Struggling with this movement often leads to reduced independence and a poorer quality of life.

My goal is to bridge the gap between high-performance, expensive medical exoskeletons and the urgent need for practical, affordable wearable assistance

Exosuit Mechanical Design

Project Overview: A Hybrid Approach

To make this exosuit a reality, I am pursuing a hybrid design philosophy. Traditional rigid exoskeletons are heavy and expensive, while purely soft exosuits struggle with stable force transmission. My design hits the sweet spot by:

  • Integrating 3D-printed rigid structural/ composite material elements with flexible textile interfaces for comfort and stability.
  • Utilising a Quasi-Direct-Drive (QDD) actuation paradigm powered by a high-torque brushless DC (BLDC) pancake motor.
  • Designing a custom gearbox at the hip joint to achieve high mechanical transparency during unassisted movements (like walking) while delivering active assistance when the user tries to stand up.

     

    Integrating 3D-printed rigid structural/ composite material

Results and the Impact of RS Funding

Transitioning from software simulations to a physical prototype is where the real fun (and challenge) begins! The funding from the RS Student Fund is playing a massive role in making this hardware a reality. It allows me to source the high-quality BLDC motors, advanced embedded motor controllers, and the necessary materials for my custom gearbox and structural frame.

Conclusion

I hope my project inspires some of you to look into the world of biomechanics and assistive technology. Engineering has the power to directly improve people's daily lives, and I can't wait to share my progress and the final results with all of you.

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