Researchers at the Fraunhofer Institute for Machine Tools and Forming Technology (IWU) have developed a highly personalized hand exoskeleton designed to help people regain mobility after injuries, strokes, or neurological conditions. Unlike generic rehabilitation devices, this exoskeleton is custom-built to match the exact shape and movement needs of each individual hand—making it more effective, comfortable, and accessible for patients of all ages and genders.
Hand mobility is often impaired after tendon damage or neurological trauma, and recovery can be slow and frustrating. Exoskeletons are increasingly used in therapy to support wrist and finger movement, but many are bulky, poorly fitted, or too heavy—especially for women and children. Fraunhofer IWU’s approach solves this by using advanced 3D printing and digital modeling to create a lightweight, anatomically precise device that fits like a second skin.
The process begins with a 3D scan of the patient’s hand, capturing not just its shape but also the proportions and relationships between different parts. This data feeds into a parametric CAD model, which allows engineers to build a “negative” of the hand and adjust it as needed over time. The exoskeleton is printed using selective laser sintering (SLS), a technique that builds up the structure layer by layer from plastic powder. This method offers nearly unlimited design flexibility and ensures a snug, personalized fit.
But fit alone isn’t enough—the device also needs to move naturally. That’s where the drive system comes in. Developed by Alina Carabello, a Ph.D. candidate at Fraunhofer IWU and research associate at Chemnitz University of Technology, the system uses a bidirectional stepper motor and shape memory alloy (SMA) wires to control movement. These wires act like artificial tendons, contracting when heated by a small electrical current and relaxing when cooled. This allows the exoskeleton to gently flex and extend the fingers with precision and safety.
The result is a device that can assist with everyday tasks like gripping a water bottle or typing, while also supporting therapeutic exercises. It’s especially helpful for patients with reduced grip strength, and its lightweight design makes it easier to wear for extended periods. Because the system is modular and digitally modeled, future adjustments or replacements can be made quickly and efficiently.
This innovation reflects a growing shift toward individualized medical technology—where devices are tailored not just to a diagnosis, but to the unique anatomy and needs of each person.
Article from Fraunhofer IWU: As Unique as Every Hand: Exoskeletons Helping Patients of All Ages and Genders Regain Independence
