CrutchGuard – Integrated Crutch Attachment
- Relevant Skills: SolidWorks, GD&T, Product Development, Iterative Design, Rapid Prototyping/3D Printing, Mechanical Assembly & Testing, DFM, Technical Documentation
Background
Annually, over 575,000 Americans are prescribed crutches, yet more than 70,000 crutch-related injuries occur, often from slips on wet or uneven surfaces. These secondary accidents risk reinjury or new harm. In our Engineering 29 final project, my team set out to design an attachment named CrutchGuard that enhances crutch stability, mimics natural foot motion, and reduces user risk.
Goals
The project required us to:- Develop a functional prototype
- Apply GD&T standards
- Prototype using 3D printing and off-the-shelf parts
- Test stability improvements and document key lessons, challenges, and design refinements
Design and Execution
- Design and Components:
- Component A (Base): Wide platform with anti-slip rubber, increasing ground contact area for stability on uneven terrain
- Component B (Support): Round design enabling rotational flexibility and smoother crutch motion
- Component C (Clamp): Adjustable system providing secure attachment to the crutch shaft
- Component D (Lock Mechanism): Connects clamp and leg, allowing rotational freedom
- Component E (Leg Connector): Future-proofed for extendability to match different crutch height
- Tolerances & Fits:
- Specified interference (LN1) and sliding (RC5) fits across critical interfaces (e.g., Base–Support, Support–Leg) to ensure both secure locking and necessary motion
- Prototyping:
- Fabricated parts with PLA using a Bambu P1S 3D printer
- Integrated off-the-shelf bolts, locknuts, heat inserts, and threaded nuts
- Reflection and Iteration:
- Grip layer added to base significantly improved traction
- Locking mechanism redesigned in concept phase for quick detachment without tools
- Proposed curved base shape for smoother walking motion, better simulating foot roll
Outcome
- Produced working prototype that enhanced crutch stability
- Validated GD&T fits through assembly and component interaction
- Identified improvements: detachable locking, adjustable height lock, and ergonomic curved base
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