Mechanical optimization of a rehabilitation harness via an integrated Abaqus-ISIGHT framework: A multidisciplinary approach for enhanced biomechanical performance

Medical-device-related pressure injuries resulting from mismatched human–harness interfaces during body weight support (BWS) training represent a persistent challenge in clinical rehabilitation. This study investigates a multidisciplinary cosimulation framework integrating finite-element analysis (FEA) and optimization algorithms to enhance the biomechanical compatibility of harness systems. An automated multisoftware optimization workflow was developed to minimize stress and strain induced by the harness, with the objective function targeting optimal pressure distribution across the body–harness interface. Subsequently, inverse parameter identification was performed to derive the optimal material properties of the harness. Simulation results revealed that the optimized harness configuration significantly reduced peak von Mises stress by 15.47% ± 1.2% and maximum shear strain by 19.58% ± 0.9% compared with conventional designs. Furthermore, a region-specific material optimization strategy was implemented: stiffer, warp-dominant materials were employed in the lumbar region to enhance load-bearing performance, while softer materials with lower warp and weft stiffness were applied to the shoulders and legs to redistribute mechanical loads and reduce localized tissue deformation. These findings provide a biomechanically informed design strategy that effectively mitigates the risk of pressure injuries during BWS training, contributing to safer and more comfortable rehabilitation harness systems.