From sculptural modeling to high-tech orthopedic device
3D scanning and sculptural modeling
Work on the boot began with capturing real anatomy — we used professional 3D scanning to create an accurate digital model of the foot. The first prototypes were created using sculptural modeling, which allowed us to find ideal ergonomics and pressure distribution.
Topology optimization
At the next stage, engineers translated the organic form into an engineering model optimized for stress. Using CAE calculations, we removed excess material while maintaining rigidity in critical areas. The result is 40-60% lighter than traditional plaster casts, while the boot withstands repeated cyclic loads.
Field testing and feedback
Each of the dozens of iterations underwent intensive field work. More than 40 prototypes were tested on real patients under the supervision of traumatologists and rehabilitation specialists. Doctors highly appreciated the model's contribution to early rehabilitation: the ability to walk without crutches as early as the 2nd week after surgery, reduced swelling, and patient psychological comfort.
Load measurement and control system with visualization and remote access
We have developed a completely autonomous electronic module that turns a regular orthopedic boot into a "smart" rehabilitation device.
FSR sensor and processing algorithms
At the core is a high-precision force sensing resistor (FSR) integrated into the sole. The system continuously measures force and displays it as a percentage of the maximum allowed. This gives the doctor an objective tool to monitor compliance with partial weight-bearing regimes.
WiFi access point and web interface
The device creates its own WiFi network — no internet or app installation required. The patient or doctor connects with any smartphone, sees the load graph in real time, and can remotely set the limit and perform calibration. This makes the technology accessible in any clinic, even without IT infrastructure.
9 generations of sensor prototypes
The journey from the first idea to a stable industrial sample took 9 consecutive iterations. Each prototype was tested for accuracy, zero drift, resistance to temperature changes, and multiple load cycles. The result is a sensor with less than 5% error and up to 72 hours of battery life during active use.
What the Smart Orthopedic Boot intelligent system can do
The technology turns the patient's subjective feeling into objective, measurable data.
📊 Force measurement
Continuous load monitoring as a percentage. Allows the doctor to accurately track recovery dynamics and teach the patient proper weight distribution.
🎛️ Individual calibration (TARE / FULL)
TARE eliminates the influence of sensor position, FULL sets the patient's maximum force. Personalization of the scale for each individual for correct percentage operation.
⚠️ Load limit (LIMIT)
The doctor sets a safe threshold (30%, 50%, 70%). When exceeded — instant notification. Compliance with prescriptions becomes simple and clear.
🎨 Color indication (Biofeedback)
Green → safe zone, yellow → approaching limit, red → exceeded. The patient instantly understands whether they are loading the leg correctly.
🔊 Sound alarm
Additional control without visual contact. Especially useful when walking, when the gaze is directed forward rather than at the screen.
📱 Smartphone web interface
Direct connection to the device's WiFi. Real time, load graph, remote limit/tare/full control. Works with any smartphone without installing applications.
🔋 Energy efficiency
WiFi turns on only when needed, automatic screen brightness reduction, optimized power consumption. Up to 3 days of battery life with active use.
🏥 Clinical application
Traumatology: control after surgeries. Rehabilitation: gait restoration and load symmetry. Sports medicine: overload prevention.
Key system advantage
The device doesn't just measure load — it teaches the patient to feel the correct force. This moves rehabilitation from subjective ("feels normal") to objective ("load 42%, target 50%"). Doctors involved in testing confirm: with our system, patients master the correct walking regime faster, and the risk of re-injury is reduced.