Arm & Leg Ergometer
A BioSpine Project
Project Period
Summary
12 Weeks
Year Developed
2025
Design Field
Medical Equipment
This project focused on the design and development of a contralateral upper–lower limb ergometer for spinal rehabilitation. The aim was to address key limitations in existing rehabilitation equipment by enabling more functional, asymmetrical movement while integrating with BioSpine’s existing systems.
Working closely with clinicians and participants, I led the project from early concept through to a functional prototype, balancing human-centred design considerations with strict mechanical, safety, and cost constraints. The resulting concept demonstrated clear clinical value and future potential for both clinical and home-based rehabilitation.
Role
Scope
Skills
Lead Industrial Design Intern
Concept → Functional prototype → Future Iterations
Human-centred design in a clinical context
Rapid prototyping under tight constraints
Mechanical design & retrofitting to existing systems
Collaboration with clinicians and non-design stakeholders
Design for safety, adjustability, and accessibility
Design Challenge
Most existing upper-body ergometers were either standalone, simultaneous in motion, or limited to small, ineffective movement ranges. These configurations offered little benefit for contralateral rehabilitation and failed to accommodate the needs of patients with unilateral or asymmetrical mobility.
The challenge was to design a contralateral system that enabled larger, more functional movement, while remaining adjustable, safe, and robust across a wide range of spinal cord injuries. The solution also needed to retrofit onto an existing motorised ergometer base, integrate with BioSpine’s system architecture, and be developed under a strict sub-$200 prototyping budget.
User & Context
The primary users were patients with spinal cord injuries resulting in paralysis from the waist down, with varying levels of upper-body strength and control. Clinicians and physiotherapists acted as secondary users, requiring the ability to assist movement, make quick adjustments, and ensure safe operation during rehabilitation sessions.
The design was developed within a clinical rehabilitation setting, beginning as a research-focused prototype while considering longer-term pathways toward clinic and home-based use. Safety, adjustability, durability, and ease of clinician interaction were critical drivers throughout the design process.
Final Outcome
The project culminated in a functional physical prototype supported by a complete CAD package, demonstrating a viable contralateral upper–lower limb ergometer system. The prototype successfully integrated with an existing ergometer motor and frame, delivering a significantly increased and more meaningful range of motion while meeting safety and strength requirements.
The concept was approved for further development, presented to clinicians and investors, and led to my continued involvement in advancing the design beyond the initial prototype phase.