ME_234_Final_Project

Ghazvini Armitter Drake Ramirez !1
BUILD-A-BRACE
TEAM #11
ALIDOD GHAZVVINI
RIVER DRAKE
JULIANE ARMITTER
VINCENT RAMIREZ

I. TABLE OF CONTENTS
Original Project Ideas………………………………3
Analysis of Problem………………………………..4
Problem Definition…………………………………6
Ideas We Developed……………………………….7
Idea We Selected………………………………….11
Final Solution……….……………………………14
Detailed Drawings………………………………..22
Cost Breakdown…………………………………..23

II. ORIGINAL PROJECT IDEAS
A. The following list are the problems we collected:
1. Bike lock is not locked/closed properly and it’s hard to tell
2. Leaving your apartment without your keys/not being able to find keys
3. For people in wheelchairs- how to reach a top shelf
4. For people in wheelchairs- the strain on the arms from pushing the wheelchair all the
time
5. For colorblind people- how to correctly identify colors for a specific job like electrical
work with the colors of the wires
6. For people in wheelchairs- how to be able to go through the sand on the beach
7. Riding your bike in the rain and the rain pelts your face and you can’t see
8. Staying up late and getting hungry again but not wanting to eat
9. For people with amputated fingers/arms- typing on a laptop/computer/tablet/phone
10. People in wheelchairs: fitting the whole wheelchair into a car. The size is somewhat
unfriendly
11. People in wheelchairs: getting hands dirty from the tire. (example of rainy day, going
through the mud
12. Wheelchairs- clothes caught in the wheel (skirts, long dress, basketball shorts, etc.)
13. Wheelchairs – most people have problems with being able to see themselves in the
mirror because the seat of the wheelchair isn’t elevated high enough.
14. Person with a sling on- removing clothes or putting clothes on
15. Person with sling on- showering
16. Person using crutches- uncomfortable in the armpit area.
17. Redesigning an ankle brace
B. The problem we selected…
IDEA #17: Redesigning an ankle brace.

III. ANALYSIS OF PROBLEM
After coming to a consensus for the main problem of the project, our team had it’s first meeting
where we raised a variety of questions to discuss certain problems of the ankle brace. After
talking to individuals who have worn or are currently wearing an ankle brace/foot orthosis and
through in-depth online research, we have discovered these main problems.
A. Sahand
Background
Alidod’s childhood friend Sahand is currently wearing an ankle foot orthosis to create
stabilization for his lower leg. During an interview with him, he spent time discussing with us the
pain he faces while wearing the device.
Problems
1. Velcro and plastic causes skin irritation in hot temperatures
2. Did not work with a variety of shoe styles; it only worked with athletic and running
shoes
3. Created fatigue for long periods of time since the sole was plastic so there was no sense
of comfort at all.
4. The device is very bulky because it goes all the way to about 3-4 inches below the knee.
5. The bumpers between the two parts of the brace would wear out easily and hence make a
clicking sound when I would walk.
6. Very limited in muscle capability
B. Online Research
Ankle Foot Orthosis (AFOs)
• Definition: medical device that controls, assists, and stabilizes the ankle joint.
• It is essentially used for people who have severe weakness in the ankle and foot area.
• It could also be used for people who have foot drop.
• goal of the device is to limit movement for leg support.

• usually made of plastic
• Deals with these problems:
• muscle weakness (drop foot)
• drop foot: caused by stroke, spinal cord injury, muscular dystrophy, peripheral
neuropathy
• Two different type of AFOs
• Static AFOs
• L shaped SFO with positioning behind the calf area.
• its used more for people who are weakened or paralyzed in the lower leg area
• some people get drop foot from a stroke
• blocks movement in any form in the ankle.
• helps control adduction
• Dynamic AFOs
• this one facilitates body motion
• It allows more movement but it isn’t as efficient in terms of healing the ankle/lower leg
area.
Ankle Brace
• immobilize the ankle joint so it can allow it to heal.
• Tight pressure allows heat and compression to flow into the bones.
• General design is used for short term injuries.
• Creates more efficiency for walking and performing daily activities
• Some designs will incorporate metallic plates that will better immobilize the joint.

IV. PROBLEM DEFINITION
In lieu of these problems, we have decided to create a brace that is mostly customizable,
comfortable, fits with many shoes, and is reliable when performing daily activities. The main
intent of the device is to create a flexible system where the user can have minimal support in the
ankle area all the way up the shin area. Furthermore, the brace will be worn like a sock so there
will not be any sort of attachment to the shoes. The user will be able to put on the brace by
themselves assuming they have the capability to or they have someone else helping them. Our
main goal of this device is to add a variety of components that allow the user to customize their
level of support. In essence, the goal of the device is to allow the patient to deal with short term
and long term ankle pain. In order to improve durability, our team will add numerous
components that allow the user to replace some parts of the brace should something go wrong.
By the deadline, we will have a SolidWorks representation and if time permits, we will have a
working prototype available during the presentation. The cost of the device will be between $30-
$100 depending on materials.

V. IDEAS WE DEVELOPED
A. Vicente’s design
A. Explanation
An idea that arose was an ankle brace that would allow for stability in the ankle joint, but not
complete immobility because that could weaken the ankle and cause damage to other joints due
to the stresses that would be put on them. So we thought of a solution that would allow for both
flexibility and stability so the joint would be safe and undergo a full recovery. Ideas for the
material that would allow for this was a high elastic fabric such as spandex. Another issue that
was addressed was the ability to adjust the height of the brace. One way we thought of doing this
was to attach velcro straps to the bottom of the brace so that it can be opened, adjusted and then
strapped back together once the desired height is achieved because not everyone wants it to be
known that they are wearing a brace. To tighten the brace, elastic laces with velcro straps
attached to them could be used. These “laces” come out of the back of the brace and can be
wrapped around the joint and strapped together again by the velcro.
B. Drawing

B. Alidod’s design
A. Explanation
The basis of the idea is to design a device that solves short term ankle pain (i.e. sprained
ankle, minimal arthritis) and long term ankle pain (drop foot, severe arthritis). In essence, the
design is simply a combination of an ankle brace with a foot orthosis put together. The benefit of
this design is to allow the user to customize it’s brace by removing components that would not be
needed. Verbally speaking, the design consists of a simple ankle brace that has its own built in
cushion in the sole area. This will allow the user to experience full comfort at all times!
Furthermore, the design has three straps that is pulled from one side of the brace to the other side
to allow pressure for stabilization. Furthermore, to solve the second problem of dealing with long
term ankle pain, there is a pocket in the back of the sock like device that allows the user to insert
a plastic slider. The dimensions of the pocket is strictly aligned with the plastic component so it
won’t fluctuate and can fully support the lower leg in general. On the side of the plastic slider are
latches that are attached to straps that strap around the patient's lower leg.
B. Drawing

C. River’s design
A. EXPLANATION
Based upon previous experience with ankle braces, River suggested this idea. It starts like a
compression sock with laces, and one strap at the top. With the laces, the user can vary the
pressure on different parts of their foot and ankle joint. From here, there are attachment sites,
such as pegs, that you can attach multiple different attachments onto to increase customizability.
This way, it would work for people who only needed a little support, but then it could also work
for those that have injuries and need complete stabilization and, of course, everybody in
between.This design was based mostly on customizability and meeting a variety of different
levels of support needs. Multiple different materials would be used for this design, such as a hard
plastic for lateral supports, stretchy fabric for the sock itself, fiberglass for the base of a foot
orthotic, and maybe various foams for padding. The components include but are not limited to:
extra straps, lateral plates, rear stabilizer, and foot orthotic.
B. DRAWING

D. Juliane’s design
A. Explanation
The idea we had was a really stable solution. The bottom and the back part are made out
of hard plastic and give the leg and the ankle a lot of support. The parts on the side can be closed
with velcro and hold the brace in place and also give support to the whole leg. Between the
bottom part and the back part of the brace is a hinge so that the foot can still move. Because we
wanted to make the bracelet really flexible in use and fit for a wide range of people the back part
of the leg brace can be extended or removed when needed. We thought that a “clip-on” system
would work best for this purpose. Furthermore there is the possibility to attach different kind of
soles (a cushion one, an orthopedic sole,..) with velcro. That way the ankle bracelet can be
helpful for many different people and needs.
B. Drawing

VI. WHAT IDEA WE SELECTED
A. Priorities for the Design
Throughout the design process, our team discussed the order in which component of our device
will be the most important. Our team agreed on this particular order.
1. Customizability
2. Comfort
3. Safety
4. Durability
5. Aesthetic
6. Cost
Reasoning behind Priority List
There were a variety of reasons our team chose our priorities in this particular order for
the design of the brace. First, our problem definition explicitly states how we want to design a
device that solves short-term and long-term ankle problems. Because short-term ankle pain and
long-term pain carry different problems for an individual, our goal is to focus on creating a
device that allows the user to adjust the brace in any way they may desire. Comfort was the
second priority because the whole goal of the device is to allow the user to feel comfortable,
almost to the extent that the user feels just as comfortable as if they are not wearing a brace.
Safety came third. It is obviously very important that the device keeps the user safe from creating
any more problems with their ankle. Another thing to note is that we chose Aesthetics and Cost
as our last priority. Our reasoning behind this decision was that our goal is to help the user to
heal. The design is not supposed to be the simplest design because if we went towards that path,
we wouldn’t be satisfying the customizability factor which is our number one priority throughout
the design process.

B. Weighted Decision Matrix
A. THE TABLE
B. ANALYSIS OF THE RESULTS
Based on the weighted decision matrix, it seemed like we were going to pursue River’s
design; however, after constantly reviewing each design, we thought that everyone’s design had
something creative and effective towards a final solution. For example, from Alidod’s design, we
liked the idea of incorporating some sort of a pocket that allows the user to add a plastic plate in
the back that allows the user to create more immobility in the ankle joint. This creates more
customizability because if a patient is dealing with a case where the ankle pain is a short terms
situation, they can easily remove the plastic plate in the back. From Juliane’s design, we were
very fond about the idea of adjusting the position of the plastic plate in the back. In essence, her
design consisted of pegs that allows the user to extend the plate higher up on the leg for
additional support if needed. From Vincent’s design, we liked the idea of the position of where
the strap with the velcro’s are located. He had two on each side that allowed the user to wrap it
around any part of the leg they wanted. This creates more customizability for the user to tighten
Weight Factor Juliane Alidod River Vincent
Durability 0.06 +1 +1 +1 -1
Cost 0.05 -1 -1 0 +1
Safety 0.2 0 0 +1 0
Aesthetics 0.14 +1 0 0 -1
Comfortability 0.25 -1 +1 +1 +1
Customizability 0.3 +1 0 +1 -1
Sum of +1 3 2 4 4
Sum of -1 -2 1 0 3
Total 0.24 0.26 0.81 -0.7

up any part of the ankle that creates more stabilization for the ankle. Therefore, we decided to
use the basic idea of River’s design and incorporated other design ideas from Alidod’s, Vincent’s,
and Juliane’s.

VII. FINAL SOLUTION
A. Initial Design
Initially, our team came up with this design as our final solution. We were satisfied with the
overall structure of the design but we noticed some flaws. Firstly, we noticed that the plates on
the side were not as effective. The reason it wasn’t an effective design was because the user will
still be able to rotate his or her foot from side to side. This would completely ruin the design
because the user will not be restricted from moving the ankle.

B. Refining to the final solution
Despite our dissatisfaction with the design, we decided to make small adjustments to come up
with our final design.
C. BRIEF BACKGROUND ON FINAL SOLUTION
Our final solution is a combination of all the Ideas listed above (idea 1-4). As a base, we decided
to have a sock that gives stabilization to the foot and the ankle. It will be easy to put on because
ME 234 - FALL 2015
Lab Section: N/A Assignment #N/A
Nxt Asb: 234-12 Chkd. By: ME STAFFDate: 11/26
Drwn. By: RIVER DRAKE
Dwg. #: 234-11
Title: ASSEMBLY
Scale: 1=8
Cal Poly Mechanical Engineering

the laces will allow it to open up wide and then make it as tight as needed. So if people just want
to have a little support for their ankle, that would be a good solution for them. However, because
we want to make the brace for a wide range of people there, there will be an add-on for people
who need more support with their foot. In order to incorporate the ankle foot orthosis part of our
project, our ankle brace will have a pocket at the back so we can slide a hard plastic stabilization
into the sock. This hard plastic plate will have straps that make it possible to attach it to the leg.
Assuming the person needs even more support, there are side plates made out of polypropylene
plastic that are hooked onto the side of each brace. This is applied for more additional pressure
onto the ankle joint because it creates more stabilization along with additional immobilization
which is what the ankle needs in order to heal. Also we have added two straps onto the brace that
the user can wrap around the foot and ankle area for more support. The straps are there only if
the user desires additional support.

D. ASSEMBLY
1. The tongue of the device is sewn onto the brace base.
2. The default strap is attached to the housing plate via slots in the plate (not shown).
3. The housing plate is pinned (with the pin) to the inner plate. The whole part is then placed
inside the pocket of the brace base.
4. The small straps are sewn onto the back of the brace base.
5. The side plates are hooked on the pegs of the brace base. Note that the bottom two holes are
used for the side plates.
6. The side plate strap will be attached to the inner part of the side plate via a velcro and onto
the brace base via a slot in the bottom.
7. The velcro strap is hooked onto the top peg of the brace base.
4
11
10
9
1
8
2
7
3
6
5
8
ME 234 - FALL 2015
Nxt Asb: N/A Chkd. By: ME STAFFDate: 11/26
Dwg. #: 234-12
Title: EXPLODED ASSEMBLY
Scale: 1=10
ITEM NO. PART NUMBER DESCRIPTION QTY.
1 234-1 BRACE BASE 1
2 234-2 TONGUE 1
3 234-3 HOUSING PLATE 1
4 234-4 PIN 1
5 234-5 SMALL STRAP 2
6 234-5 DEFAULT STRAP 1
7 234-6 INNER PLATE 1
8 234-7 VELCRO STRAP 2
9 234-8 SIDE PLATE (LEFT) 1
10 234-8 SIDE PLATE (RIGHT) 1
11 234-9 SIDE PLATE STRAP 1

E. Component
Name of Component Function Material Why we used that
Material
Brace Base The main part of the
brace
Sock - Neoprene
Pegs- Acrylic
Neoprene- This is to
allow breathability but
also elasticity to the
brace. Neoprene is also
comfortable and is
strong enough to be the
main portion of the
brace.
Acrylic- This is because
the pegs hold different
parts on the brace, and
we wanted to make sure
that they were strong
enough to handle it and
also light enough so that
the brace wasn’t too
heavy.
Tongue Protects the skin from
the laces and adds extra
comfort
Neoprene This is because it is easy
to sew two like
materials together and
also because this also
has to be a very
comfortable part of the
brace. Neoprene is also
very durable in water as
it does not stretch like
regular fabrics do,
which loosen stitches
and make the seam fall
apart faster.
Inner Plate Provides a rigid back to
support the rear of the
ankle joint
Acrylic Acrylic can be
manufactured easily and
is very cheap. It can
also be made into many
different colors and if
prepared correctly, is
very strong. Since it is
so easy to manufacture,
it can be replaced very
easily, which is why we
decided on it.
Housing Plate Extends the reach of the
inner plate to allow for
more support higher up
the calf.
Acrylic This is for the same
reasons as listed above.

F. ANALYSIS
A. CONNECT TO PROBLEM DEFINITION
Our final design has satisfied every part of our initial problem statement. Firstly, we
solved all our priorities in the particular order selected. The brace is fully customizable so if the
user does not want the plastic plate in the back, they can easily remove it. The brace can then be
used for short-term ankle pain. The device is very comfortable because the user will treat the
device as if they are wearing a regular sock. The only obvious difference is that there are
components attached to the upper part of the sock (in the ankle area) that is used for stabilization
in the ankle. The device deals with any sort of ankle pain, so if a person has arthritis in the ankle
area, the plate in the back (inserted in the pocket) will be used for long term solution to the
Pin Holds the Inner Plate,
and the Housing Plate
together.
Manufactured
Aluminum (6061)
Aluminum is also very
manufacturable, light,
and cheap. Because of
these factors, it is also
easily replaced, which is
why we chose it for this
part.
Straps Attaches several
components to the
user’s leg.
Spandex with velcro We chose spandex
because like the
neoprene, it needs to be
comfortable because it
will be in direct contact
with the skin. It also
needs to be elastic
enough to stretch
around their leg. In
order to attach, we’ve
decided on velcro.
Side Plates Provides lateral support
for the ankle
Polypropylene Polypropylene is a hard
plastic that is strong and
can be plastically
deformed without
breaking. We’ve chosen
this material because it
is durable, but also
strong enough to
provide the support the
user needs.
Name of Component Function Material Why we used that
Material

problem. As noted in the exploded view, there are 11 different components that is built into the
device which solves our goal of creating a device with a lot of different parts. This allows more
durability because if one the pieces wear out, they can easily replace it.
B. HOW IT SATISFIES THE FOLLOWING FACTORS
Aesthetics:
In terms of the design, our device does not have the most appealing look compared to
other devices. When our team discussed our priorities, aesthetics was towards the bottom
because if our solution was to include a variety of components to make the device more durable,
we had to sacrifice the looks of the device, meaning it wouldn’t look as nice as other braces the
user would see in the market.
Human Factors/Liable/Safety:
This device can be used for anyone. While wearing this brace, the user can use almost
any shoe as well. Only adjustment the user might have to make is purchasing a shoe size about
half an inch bigger than their usual size. Secondly, since there are metallic plates on the ankle
area, a user might feel uncomfortable for high-top shoes (i.e. boots). The solution to this problem
is for the user to purchase a bigger shoe (approximately 1 size bigger). This brace will be
designed for both the left and right foot. In terms of safety, the user must be responsible at all
times when wearing the device. The device is obviously safe enough for the person to do any
daily activity (i.e. walking to class, driving, hiking), but they should take caution while engaging
in vigorous activity because the brace could restrict their movements in such a way they might
get injured.
Expectations of Efficiency:
We hold high standards for this design. In essence, our goal for this design is to treat any
sort of ankle problem. Therefore, this device will be considered to have high efficiency because
the components added to the base of the brace will allow high immobilization of the ankle,
creating more stability for the joint. There are four straps where the user can wrap around the
ankle and foot to allow that area to be highly restricted in terms of its movement in all axis of
rotation. Furthermore, the plate in the back will be used to allow more support in the lower leg in
general.

Effects on Environment:
With the materials used, we are concerned that the plastic used could pose an effect on
the environment. However, based upon the purpose of the device we don’t suspect it will affect
the sale of the product.
Life Expectancy:
As we mentioned earlier, we added a variety of parts to this device so should something
go wrong with one of them, the user could easily replace that part upon their request. We’ve also
chosen materials that are durable in many conditions. The expectancy of this device is for it to
last up to 3-5 years.

VII. DETAILED DRAWINGS
ME 234 - FALL 2015
Dwg. #: 4
Title: HOUSING PLATE
Scale: 1=2
EXTRA HOLES FOR SUPERIOR CUSTOMIZABILITY
HOLE USED TO PIN INNER PLATE TO THIS HOUSING PLATE
SLOT FOR INNER PLATE TO FIT
/A Assignment #N/A
Drwn. By: RIVER DRAKETitle: ASSEMBLY
Scale: 1=8

DIFFERING WIDTHS IS DUE TO THE LOCATION ON TEH BRACE AND HOW MUCH SUPPORT IS REQUIRED.
ME 234 - FALL 2015
Dwg. #: 7
Title: MAIN STRAP
Scale: 1=4
VELCRO TO ATTACH TO ITSELF,
IN ORDER TO SECURE THE STRAP
LARGE VELCRO AREA TO ENSURE
A WIDE VARIETY OF SIZES AND TIGHTNESS
ME 234 - FALL 2015
Dwg. #: 5
Title: SIDE PLATE STRAP
Scale: 1=2

ME 234 - FALL 2015
Lab Section: N/A Assignment #
Dwg. #: 3
Title: PIN
Scale: 4=1
ME 234 - FALL 2015
Dwg. #: 8
Title: TONGUE
Scale: 1=2
TO BE SEWED TO THE BRACE BASE IN PRODUCTION

ME 234 - FALL 2015
Dwg. #: 6
Title: SIDE PLATE
Scale: 1=2
HOLES TO ATTACH IT TO BRACE BASE SLIT FOR THE SIDE PLATE STRAP TO ATTACH
LACES WILL SECURE SOCK TOGETHER
SLITS FOR STRAP ANCHOR
ME 234 - FALL 2015
Dwg. #: 1
Title: BRACE BASE
Scale: 1=4
VELCRO ATTACHMENT SITE
PEGS HOLD VARIOUS ADD-ON COMPONENTS

HOLE TO ATTACH TO PEGS ON BRACE BASE
VELCRO TO SECURE STRAP TO BRACE BASE
Dwg. #: 9
Title: VELCRO STRAP
Scale: 1=3ME 234 - FALL 2015
Drwn. By: RIVER DRAKECal Poly Mechanical Engineering
ME 234 - FALL 2015
Dwg. #: 2
Title: INNER PLATE
Scale: 1=2
HOLE TO ATTACH TO THE OTHER PLATE
IF MORE SUPPORT IS NECESSARY.

X. COST BREAKDOWN
Initially, we will make a number of our leg braces for a small population in the San Luis Obispo
area. However, based on our feedback and demands of the consumers, we will further invest into
the manufacturing of our leg braces.In order to determine the amount of money we will be
investing to manufacture each leg brace, several factors need to be included.
A. Sizes
Above are the listed sizes for both men and women. We offer a selection of 3 different sizes
ranging from small to large, with medium being in between. Our chosen material neoprene, due
to its elastic nature can accommodate over 90% of the population. The cost in manufacturing will
vary due to the necessary materials needed for bigger sizes.
B. Cost of Raw Materials
U.S. Size Women U.S. Size Men Size Fits for the Device
< 6 < 8 Small
7-8 9-10 Medium
9-10 11-12 Large
Materials Components Price ($) Notes
Neoprene Sock and tongue 3.79 Solid in sheets of
12”x12”
thickness: 1/8”
Acrylic Inner/Housing Plates 34.86 Sold 24” x 24”
thickness: 0.236”
Velcro (fasteners) Straps 12.99 Sold 2” x4’
thickness: negligible
Aluminum Pin 9.99 Solid .5” x 10”
(4 pieces)
Spandex Straps 4.99 Sold 3/25” x 30’
thickness: 1/8”
Polypropylene Side Plate 47.84 Sold 12” x 48”
thickness: 3/4”

Above is a table for the cost of the raw materials that are incorporated into our design.
Total cost to manufacture 1 unit is approximately: $64.99. However, this includes many left-over
materials. The cost can be further analyzed as long as we have the dimensions of our unit and
necessary materials that will be used to make one. We can then approximate how much it would
cost to make one unit, and how much we will sell it for. After that, we can talk about the profit
we plan to make.

ME_234_Final_Project

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