Abstract
Knee injuries and mobility impairments often require long-term rehabilitation, for which robotic exoskeletons have shown clinical potential. However, many existing devices are limited by high weight, poor adjustability, and insufficient torque generation, which restrict their usability in real-world clinical settings. This study aimed to design and evaluate a lightweight, adjustable knee exoskeleton with enhanced ergonomics and functional performance for rehabilitation. The exoskeleton was developed using CAD-based structural optimization to balance strength and weight. Materials were selected based on load-bearing requirements, combining acrylonitrile butadiene styrene plastic for lightweight construction with reinforced steel components for critical joints. A brushless direct current motor was employed for actuation, and the system was designed to provide three-axis alignment adjustability. Simulation studies assessed torque capacity, weight distribution, and biomechanical feasibility. The optimized design achieved a projected weight of less than 7 kg, representing a significant reduction compared to conventional devices. The actuation system generated torques up to 120 Nm, sufficient to support common rehabilitation activities. Biomechanical simulations demonstrated that the exoskeleton was feasible for walking, sit-to-stand, and stair-climbing movements. The adjustable alignment mechanism improved ergonomics, accommodating different body types and reducing the risk of joint misalignment during use. The proposed knee exoskeleton, with its lightweight structure, high torque capacity offers a promising solution for clinical rehabilitation. Compared to existing designs, it provides improved safety, comfort, and adaptability, making it suitable for diverse rehabilitation scenarios. Future work will involve prototype fabrication, experimental validation, and pilot clinical testing.Keywords:exoskeleton device, rehabilitation, knee joint, gait, walking, postural balance