Bioinspired Design of Ergonomic Tool Handles Using 3D-Printed Cellular Metamaterials

The design of ergonomic tool handles is crucial for user comfort and performance, yet conventional stiff materials often lead to uneven pressure distribution and discomfort. This study investigates the application of 3D-printed cellular metamaterials with tunable stiffness, specifically gyroid structures, to enhance the ergonomic and haptic properties of tool handles. We employed finite element analysis to simulate finger-handle interactions and conducted subjective comfort evaluations with participants using a foxtail saw with handles of varying gyroid infill densities and a rigid PLA handle. Numerical results demonstrated that handles with medium stiffness significantly reduced peak contact pressures and promoted a more uniform pressure distribution compared to the stiff PLA handle. The softest gyroid handle, while compliant, exhibited excessive deformation, potentially compromising stability. Subjective comfort ratings corroborated these findings, with medium-stiffness handles receiving the highest scores for overall comfort, fit, and force transmission. These results highlight that a plateau-like mechanical response of the 3D-printed cellular metamaterial handle, inversely bioinspired by human soft tissue, effectively balances pressure redistribution and grip stability. This bioinspired design approach offers a promising direction for developing user-centered products that mitigate fatigue and discomfort in force-intensive tasks.