Designing for Therapy: An Ergonomic Hand Orthosis that Enhances Functional Recovery

Abstract

This project presents the design and development of an ergonomic, user-centered hand, wrist, and finger orthosis to support rehabilitation in pediatric users and stroke patients with neurological impairments. Conditions such as stroke and pediatric motor disorders are often associated with altered muscle tone, spasticity, and impaired neuromuscular control, limiting voluntary hand opening, extension, and functional grasp. These patients frequently exhibit flexor dominance and reduced active extension, making reach, release, and object manipulation challenging. There is a growing need for pediatric-specific orthotic solutions that address differences in hand anatomy, growth, activity patterns, and therapy engagement. The project began with a review of literature on neurological spasticity, pediatric rehabilitation, and existing orthotic devices, supplemented by discussions with therapists to understand functional limitations, positioning requirements, and safety considerations. Key design requirements included ergonomic alignment, adjustability, lightweight construction, comfort, and ease of application. Multiple concepts were developed through sketching and CAD modeling to ensure anatomical alignment of the wrist and metacarpophalangeal joints. Prototypes were fabricated using lightweight, skin-friendly materials and evaluated for fit, comfort, and range-of-motion support. The final design provides controlled extension assistance to counter flexor dominance while enabling functional grasp and release. Iterative refinement improved strap placement, joint mechanics, and structural stability, resulting in a prototype that demonstrates improved positioning, adjustability for growth, and enhanced comfort for rehabilitation use.

Keywords: Hand Orthosis, Stroke Rehabilitation, User-centered Design, Ergonomics, Neurological Rehabilitation, Assistive Therapy Design

DOI: 10.54941/ahfe1007480