3D Models

Using Fusion 360, I modeled each finger sleeve with attention to joint flexibility and flex sensor placement. The design includes:

• Segmented joints to allow for natural finger bending and extension

• Sensor integration slots for accurate motion tracking

• Rounded edges and contoured surfaces for skin comfort and prolonged use

• Custom sizing to accommodate different hand shapes and sizes

The 3D design process allowed us to prototype rapidly, test fits, and iterate based on feedback from physical models and user comfort trials. The product was printed in TPU as a balance between durability, flexibility, and lightness was needed, ensuring the final wearable device supports daily use without causing fatigue.

The hand module of the Rehab Reach device was designed to serve as the anchor that securely holds the wearable in place while allowing natural hand movement and comfort. Using Fusion 360, I developed a flexible, yet stable, structure that conforms to the user’s hand, integrating seamlessly with the fingers. Key features of the design include:

• Curvature to match the natural shape of the hand, minimizing pressure points and improving wearability

• Mounting points for attaching finger modules and embedding motion sensors or microcontrollers

• Ventilation grooves and contoured padding zones for increased comfort during extended use

• Strap guides or snap-fit enclosures to keep the device securely in place while allowing easy donning and removal

TPU was used to print this part as flexibility, biocompatibility, and durability were all essential, ensuring the device can withstand repeated use in both clinical and home environments.