PROTOTYPES & CLIENT FEEDBACK

In February 2026, Team BEARGE presented our initial forearm gauntlet prototype to Sarah Brockberg. Her feedback directly shaped our next phase of design.

Prototype 1: Forearm Gauntlet (v1)

SolidWorks CAD model of Forearm Gauntlet prototype 1 — cylindrical forearm sleeve with mounting tabs
SolidWorks CAD model of Forearm Gauntlet prototype 1.2 — updated with cutout on underside
Additional prototype view

Our first prototype is a forearm gauntlet — a rigid sleeve that mounts to the forearm and holds a racket attachment, removing the need for the student to grip the implement at all. The core design premise is that the racket is secured to the limb rather than held in the hand, redistributing the mechanical demands of a striking motion from the fingers and wrist to the forearm and arm as a whole.

The gauntlet is modeled after AFO (Ankle-Foot Orthosis) bracing principles: a form-fitting shell that distributes load across the limb rather than concentrating it at a single point of contact. This approach was selected because it eliminates the three compounding motor demands — grasp, wrist stabilization, and directional control — that collectively prevent many of Sarah's students from participating in racket-based activities.

IMPLEMENTING SARAH'S FEEDBACK: OUR NEXT STEPS

Each element of Sarah's feedback maps directly to a concrete design action in our next phase. The three components below are being developed in parallel:

  1. Redesigned Forearm Gauntlet — Neutral Wrist Geometry
    Responding to: Sarah's identification of dorsiflexion as clinically disqualifying.
    The gauntlet shell will be fully redesigned so that when worn, the user's wrist rests in a neutral position with no forced extension or flexion. The racket mounting point will be repositioned to align with the forearm's natural axis in this posture. We will draw on AFO design literature to ensure the load distribution and shell curvature are appropriate for low-mobility users, and the revised geometry will be validated against measurements of Sarah's students' wheelchairs and arm positions.
  2. Closed-Hand Grip Attachment
    Responding to: Sarah's identification of students with fixed or spastic hand closure who cannot open their hands.
    A mitt-style interface designed around a neutral closed-fist position — the natural curl of the hand at rest with no active grip required. This attachment will connect to the redesigned gauntlet and secure the implement against the dorsal surface of the closed hand, distributing contact across the hand rather than concentrating pressure at a single point.
  3. Open-Hand Grip Attachment
    Responding to: Sarah's identification of students who can open their hands but cannot grip or squeeze.
    A palm-spread interface that holds the implement against an open, flat hand without requiring active finger closure. This may use a fold-over, Velcro wrap, or molded palm cradle design. The key constraint is that the student must be able to don and doff the attachment independently or with minimal assistance, consistent with Sarah's emphasis on student dignity and independence.

We are meeting with Sarah again on Monday, March 2nd — immediately before our Preliminary Design Review — to present these three directions, validate the neutral-wrist geometry against her students' needs, and gather any additional constraints before we finalize our designs.

Prototype 2: MVP Field Test

On April 7, 2026, the team conducted field testing on the indoor volleyball courts at the CU Boulder Recreation Center, presenting the MVP to Sarah Brockberg as a first functional iteration designed to validate the core mechanical interface.

The MVP introduced two parallel hand attachment strategies: a fabric mitten (closed-hand version) and a PLA plate (open-hand version). Both connected to the racket handle via a box-and-slot system cinched with industrial-grade Velcro. The team conducted 20 minutes of active badminton play — including serves, volleys, and overhead strikes — to evaluate structural integrity and impact on the user during repetitive striking motions.

Performance Data

Metric Target Actual Status
Total Weight < 1.0 lb ~0.25 lbs Validated
Production Cost < $5.00 ~$3.15 Validated
Grip Dependency 0% Active Grip 0% Active Grip Validated
Assembly Efficiency Low Effort Low (~5 min/unit) Validated

ROADMAP FOR ITERATION 2.0

Based on testing data, three critical areas have been identified for the next iteration. Weight and cost targets are validated and remain unchanged — the universal design constraint is being expanded from fitting the arm to fitting the movement.

  1. Manufacturing Optimization
    Addressing: 30+ min/unit assembly failure.
    Test alternate printing orientations and slicer settings to find a configuration that produces clean, smooth Velcro channels without long post-processing. The goal is a print-to-play state requiring minimal cleanup.
  2. Reshaping for Joint Clearance
    Addressing: Wrist and elbow pinching during play.
    Reshape the PLA arm attachment to be more contoured near the wrist and elbow joints. By removing material where the arm needs to bend, the design can reduce interference while maintaining the rigid support the system requires.
  3. Universal Ergonomic Refinement
    Addressing: Awkward hand-to-racket interface across both variants.
    Apply consistent ergonomic work to both the Mitten and the Plate versions to ensure a standard of comfort regardless of which attachment a student uses.

Next critical test: a full 40-minute wearability trial with the reshaped version 2.0 to confirm that pinching is resolved and plate geometry is sufficiently refined.