Modular Knee Brace

thingiverse

This is a cutting-edge 3D-printed knee brace prototype designed to provide enhanced support for individuals who have suffered minor or major knee injuries. After rigorous testing, including failure tests and agility drills, the design has proven itself with exceptional results due to its simplicity. Please continue refining this design as there's still room for improvement. A few key points to note: This iteration is not intended to replace conventional knee braces entirely but rather offer a low-cost, customizable alternative. I welcome further improvements to enhance the design's performance and potential. The main focus of this design is customization to meet individual needs. To size the brace accurately, follow these measurements: Approximately 7 inches above the patella, measure around the front half of the thigh (half circumference). Approximately 7 inches below the patella, measure around the calf (half circumference). Measure across the midline of the patella for the "width" of the knee. When adjusting sizing, subtract 0.5 inches from measurements around the top and bottom parts of the brace to ensure a snug fit. Here's the bill of materials used: Moleskin was applied to the inner portion of the brace for enhanced comfort. 1.5-inch nylon straps with a buckle of your choice (I used strapworks.com) were employed. Miscellaneous padding for the straps can be as simple as headliner or custom-made neoprene padding. Print Settings Printer Brand: Stratasys Printer: uPrint SE Plus Rafts: Yes Supports: Yes Infill: Various Notes: This design is intended to be printed on any printer, but it has only been fully printed on the specified printer above. The hinge assembly's tolerance is at the printer's limit, requiring dissolvable filament as a support structure. Infill Parameters: -Hinges: 100% -All other parts: 60% or higher Post-Printing Requirements Dissolvable filament must be used for the hinges. Assembly Notes File names indicate where each piece goes (use the picture as a guide). A plastic cement is necessary to join the brace together (I used Oatley medium plastic cement). PVC Cement works well too. How I Designed This This design was created using Solidworks and a generic concept in mind. The hinge employs a press-fit joint variant.