Modular Knee Brace

grabcad

This 3D-printed knee brace prototype offers additional support for individuals with minor to severe knee injuries. It has been tested under failure and agility drills, demonstrating excellent performance due to its simple design. However, it's not intended to replace traditional knee braces completely. The low-cost, customizable option can be improved further. Key measurements for sizing include thigh and calf circumferences and patella width. When adjusting the brace size, subtract 0.5 inches from the top and bottom measurements for a snug fit. It's made of moleskin on the inner portion, 1.5-inch nylon straps with chosen buckles, and optional custom neoprene padding. The prototype was printed using a Stratasys uPrint SE Plus and requires dissolvable filament for hinge support structure. Infill percentages vary, but at least 60% is recommended. Assembly necessitates plastic cement like Oatley medium or PVC cement. Despite being tested on specific printers, this brace design can be adapted for any printer, with adjustments made for tolerance within the hinge assembly. Dissolvable filament remains necessary for hinges, which require plastic cement during assembly.