SOFT
FINE
GOODS
CONSULTING
BACK TO THE
WEARABLE TECH
PORTFOLIO
ANKLE EXOSKELETON
Developed in the Zelik Lab at Vanderbilt University, this ankle exoskeleton is designed to support rehabilitation and prevent Achilles tendon injuries.
MY ROLE:
Conducted market research, established design sprints, and led rapid prototyping for the soft goods components. My primary contributions focused on the calf sleeve and the elements securing the exoskeleton to the shoe. Earlier iterations were permanently attached to shoes, challenging to don and doff, and thermally uncomfortable. I designed a calf sleeve that maintained its position under load, significantly improved thermal comfort, and introduced an easy, quick donning and doffing system. Additionally, I developed testing protocols to validate the functionality of my designs.
DESIGN PROCESS:
This was one of the most technically demanding wearable systems I’ve worked on. Unlike back exosuits, where the softness of the human body and the stretch of textiles only slightly reduce assistance, the ankle exoskeleton was hypersensitive to unintended movement or material compression. Even a millimeter of slippage or foam compression could severely limit effectiveness. That made the design of the calf sleeve and shoe attachment especially critical.
I began by investigating all the spring-dampening factors in the system — from soft tissue deformation to material behavior under load. I conducted a detailed study to isolate anatomical structures that could resist gravity more effectively and redesigned the calf sleeve for maximum stability without sacrificing comfort. I replaced the original TPE-based sleeve with dycem to allow for quick donning and doffing, improved thermal breathability, and cost-effective production.
One of the biggest breakthroughs was collaborating closely with the mechanical engineer to develop a quick-swap attachment system for the shoe that maintained load resistance while allowing ease of use — a feature not available in any prior design. I also reworked the geometry and materials of the calf sleeve to resist motion under high loads while preserving comfort and fit.
My contributions were tested in both indoor and outdoor running studies and formed the basis for a more modular, user-friendly exoskeleton system.
DESIGN PHILOSOPHY:
My guiding principle for this project was: precision matters — and softness doesn’t have to mean slippage. In this system, even the smallest unintended movement could sabotage the assistive performance. So the design had to be rigid where needed, adaptive where possible, and uncompromising on comfort.
Key values included:
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Fit as function — because slippage is failure
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Comfort under load — not just at rest
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Swapability without sacrifice
I approached every design decision with two questions: How does this affect load transmission? and How does this affect the user’s willingness to wear it? The result was a calf sleeve and shoe interface that balanced biomechanical integrity with real-world usability — a system that supported assistive power without becoming a burden.
