From Shore-A 85 to Shore-D 70: Multimaterial Transitions in 3D-Printed Exoskeleton

Soft–rigid interfaces in exoskeletons are key to balancing flexibility and structural support, providing both comfort and function. In our experience, combining Bioflex material with a rigid filament improves mechanical properties while allowing the exoskeleton to adapt to complex hand movements. Flexible components provide adaptability, reducing pressure points and discomfort during prolonged use. At the same time, rigid components provide the stability and force transfer necessary to support weakened grip strength. A key challenge in this integration is achieving a smooth transition between materials to prevent stress concentrations that can lead to material failure. Techniques for providing adhesion and mechanical locking are essential to ensure the durability and longevity of soft and rigid interfaces. One issue we have observed is that rigid filaments can restrict movement if not strategically placed, potentially leading to unnatural hand movement. On the other hand, excessive softness can reduce the force output needed for effective rehabilitation or assistance. Optimizing the interface design requires iterative testing to find the perfect balance between flexibility and mechanical support. In some prototypes, material fatigue in soft sections led to early failure, requiring reinforced hybrid structures. Addressing these issues through better material bonding and geometric optimization can significantly improve the performance and comfort of hand exoskeletons. The aim of this study was to investigate the transition between rigid and soft materials for exoskeletons.