Fabrication Process

Materials Required

• Main Components: aluminum sheets (for the brace structure)
• High-density foam padding (for comfort)
• Velcro straps (for adjustable fit)
• Compression fabric (for additional support)

Tools and equipment

• CNC machine or laser cutter (for cutting aluminium)
• Heat press (if needed for shaping materials)
• Sewing machine (for attaching straps and padding)
• Riveting tool or screws (for hinge assembly)

Steps in Fabrication
Step 1: Cutting Materials

• Cut aluminum sheets. A CNC machine or laser cutter is used to cut aluminium sheets according to the pre-defined dimensions for the knee brace.
• Ensure edges are smooth and free from sharp points.

Step 2: Shaping and Assembly

• Shape Aluminum. If necessary, use a heat press or bending tools to mould the aluminium into the desired curvature that matches the knee anatomy.
• Assemble Hinges. Attach ratchet hinges to the aluminum structure using rivets or screws, ensuring they are securely fastened and allow for smooth movement.

Step 3: Padding and Straps

• Apply Padding. Cut high-density foam padding to fit around areas where the brace will contact the skin.
• Use adhesive or sewing techniques to attach padding securely to the aluminium structure.
• Attach Strapping System. Sew Velcro straps onto designated areas of the brace, ensuring they are positioned for easy adjustment.
• Test strap lengths to ensure they accommodate various sizes while providing a snug fit.

Step 4: Final Assembly

• Install compression fabric. Attach compression fabric around the brace to enhance support and blood circulation if applicable.
• Quality Check. Inspect all components for proper alignment, secure fittings, and overall quality.
• Test hinge movement to ensure it mimics natural knee motion without obstruction.

Testing and Evaluation

• Fit Testing. Have users try on the prototype to assess comfort, fit, and functionality.
• Performance Testing. Conduct controlled movement tests to evaluate stability during flexion and extension.
• Feedback Collection. Gather user feedback regarding comfort, ease of use, and any areas needing improvement.