Background Jaipur Foot Organization

Confidential Information
Background Motivation

○ 30+ million lower-limb

amputees worldwide
○ 300,000 above-knee amputees
in India
○ Many are excluded from
society, economy, and culture

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Confidential Information
Background
Benchmarking
Market

Jaipur Knee Stanford - Remotion Instalimb General knee prosthetics

Jaipur Knee Knee in the United States for
$15 $400 patients with a Health
~ $36 $80 Insurance

<$10,000

MIT Gear
Lab
Confidential Information
 Cost Estimation and Dependencies
Background

Market Main factors influencing costs:

○ Design complexity
○ Use of mass manufacturing processes
○ (e.g. forging, injection molding, which
guarantee high quality without piece to
piece variation)

○ Volumes
○ Material selection MIT Gear Lab

Confidential Information
 Current Design
Background

Market ○ Number of components: 60+

Present ○ Estimated cost: $1000
○ Weight: 1.5kg
○ Exposed joint (no enclosure)
○ Materials: Aluminum 7075 & 6061,
assorted fasteners, bushings,
bearings, washers, and spacers

Confidential Information
 Project Goal
Background

Market
Modify the GEAR Lab - Jaipur knee by:

Present ○ Improving safety and user experience

○ Decreasing weight
Goal ○ Covering pinch points
○ Lowering cost w/o sacrificing quality
○ Ensuring local manufacturability
○ Satisfying aesthetic requirements
○ Miniaturizing and enclosing componentry

Mechanical design of Design of

functional componentry enclosure Confidential Information
 Background
Physics
Market
Market
○ Σσmax <= σyield * (2.4 FoS) (ISO)
Present
Present

Goal
Goal
○ max vertical GRF in TF amputees =
Mechanical
DFM 101.6 +/- 5.7 % body mass (Peduzzi de
Castro et al. 2014)
Mechanical

○ 95th % Indian body mass = 76kg

(~170lbs, NFHS-3)

Confidential Information
 Load Path
Background

Market
Market

Present
Present

Goal
Goal

Mechanical
DFM

Mechanical

Photos: Martin Bionics, Trulife

Confidential Information
 Load Path
Background
Assume each possible load path bears the maximum load
Market
Market

Present
Present

Goal
Goal

Mechanical
DFM

Mechanical

Confidential Information
 Qualitative Observations
Background

Market
Market

Present
Present

Goal
Goal

Mechanical
DFM

Mechanical

Confidential Information
 Qualitative Observations
Background

Market
Market

Present
Present

Goal
Goal

Mechanical
DFM

Mechanical

Confidential Information
 Mechanical Design
Background

Market
Market

Present
Present

Goal
Goal

Mechanical
DFM ○ V𝛼b*h*l
Mechanical ○ 𝜎max 𝛼 w, l, 1/b, 1/h^2
○ Other cost drivers:
complexity, material

Confidential Information
 Four-bar
Background

Market
Market

Present
Present

Goal
Goal

Mechanical
DFM

Mechanical

Confidential Information
 Background
Four-bar

○ Use Al 6061
Market
Market

Present
Present
○ Narrow to 25mm
Goal
Goal (⅔ original width)
Mechanical
DFM
○ Condense
Mechanical around other
componentry as
possible

Confidential Information
 Background
Linkages

○ Substitute
Market
Market

Present
Present
off-the-shelf steel
Goal
Goal pins for fasteners
Mechanical
DFM
○ Condense linkages,
Mechanical use plastic with
good wear
properties

Confidential Information
 Shear

Background
Linkages
¼W

Market
Market

-¼W
Present
Present 1mm

Goal
Goal

Moment
Mechanical
DFM

Mechanical

¼W ¼W
-.8Nm

¼W ¼W Von Mises equivalent stress

𝜎’ = ( 𝜎^2 + 3𝜏^2 )^½
dmin = 4mm Confidential Information
 Background Hard stop
Market
Market

Present
Present
Substitute
press-fit
Goal
Goal
off-the-shelf
Mechanical
DFM
steel pin
Mechanical

Confidential Information
 Background Bias Spring
Market
Market

Present
Present
Build spring
support into
Goal
Goal
enclosure
Mechanical
DFM

Mechanical

Confidential Information
 Background Side Plates
Market
Market

Present
Present

Goal
Goal

Mechanical
DFM

Mechanical

Confidential Information
 Design Comparison
Background

Market
Market

Present
Present

Goal
Goal

Mechanical
DFM

Mechanical

Old vs New

Confidential Information
 Background

Market
Market

Present
Present

Goal
Goal

Mechanical
DFM

Mechanical

Old vs New

Confidential Information
 Design Criteria
Background

Market

Encasing the mechanism

Present

Keeps dust out

Goal

Contoured
Mechanical

Not load bearing

Enclosure

No pinch points

Aesthetically pleasing

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Confidential Information
 Initial Ideation
Background

Market

Present

Goal

Mechanical

Enclosure

Top cap slides under the lower cap Top cap slides over the lower cap

34
Confidential Information
 Initial Concepts
Background

Market

Present

Goal

DFM
Mechanical

Mechanical
Enclosure
Old vs New

Enclosure

35
Confidential Information
Background
Enclosure Design
Market

Present

Goal

DFM
Mechanical

Mechanical
Enclosure
Old vs New

Enclosure

Confidential Information
Background
Enclosure Design
Market

Present

Goal

DFM
Mechanical

Mechanical
Enclosure
Old vs New

Enclosure

Confidential Information
Background
Enclosure Design
Market

Present

Goal

DFM
Mechanical

Mechanical
Enclosure
Old vs New

Enclosure

Confidential Information
Background
Enclosure Parts
Market

Present

Goal

DFM
Mechanical

Mechanical
Enclosure
Old vs New

Enclosure
Top Left Top Right Bottom Left Bottom Right

Confidential Information
Background Prototype
Market

Present

Goal

DFM
Mechanical

Mechanical
Enclosure
Old vs New

Enclosure

Confidential Information
 Background
Background
Process: Assembly
Market
Market
Previous part count = 64 New part count = 17
Present
Present

Goal
Goal

Mechanical
Mechanical
DFM

Enclosure
Mechanical
Mechanical

Old vs New
DFM

Design
Enclosure

47
Confidential Information
 Background
Background Design Comparison
Market
Market

Previous design New design New/Old

Present
Present

Vol. of internal parts 152.7cm3 35.7cm3 24%

Goal
Goal
Mass (estimated, excluding 1500g 500g 33%
adapters)
Mechanical
DFM
Mechanical

No. fasteners (excluding

Enclosure
Mechanical
Mechanical damper) 14 0 0%

Old vs New
DFM No. of parts 64 17 (+ 4pc enclosure) 27%

Enclosure
Design
WOW

Confidential Information
 Previous design New design New/Old
Side plates volume
52.1cm3 5.9cm3 (Al to plastic) 11%
Knee piece volume
37.8cm3 20cm3 53%
Latch volume
32.6cm3 7.8cm3 24%
Linkages volume
10.6cm3 0.8cm3 (Al to plastic) 8%
Hard stop volume
9.8cm3 1.2cm3 12%
Spring holder volume
0 Al, small amount as part
9.8cm3 of enclosure
~0%

Vol. of above parts

152.7cm3 35.7cm3 24%
Mass of above parts
~1500g ~500g 33%
No. fasteners (excluding
damper)
14 0 0%

No. parts
64 17 + 4 pc enclosure 27%
Confidential Information
 Thank you!
Amos, Dr. Pooja, Nina, Collin, Amy, Red Cross, FUPRO…

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Confidential Information
 Team Mentor: Nina Petelina

Amari Griffin Madison Reddie Manasi Vaidya Saloni Bedi

Harvard University MIT MIT IDM MIT IDM
MBA + MS in SM + PhD in Mechanical MS in Engineering and MS in Engineering and
Engineering Sciences Engineering Management Management

Industrial Engineer Experience Designer Industrial Designer

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Confidential Information