Reconfigurable Compliant Joints (RCJs) for Functional Biomimicry in Assistive Devices and Wearable Robotic Systems

Compliant mechanisms have contributed to many advances in soft robotics, and there is strong motivation to translate these ideas to assistive devices where adaptive motion at the human interface is required. This work presents novel reconfigurable compliant joints (RCJs) as a parameterized joint element for functional biomimicry in lower-extremity joints for prosthetic knees and ankle–foot orthoses, with concepts that extend to other limb joints. The RCJ uses a rigid hub and outer ring joined by an array of flexible links with centerlines defined by cubic Bézier curves. Link shapes are organized into four Bézier classes (A–D), with base types using 10, 12, or 14 uniformly distributed link slots and variants generated by modifying active-link count and distribution, forming a structured morphology space of 12 configurations for machine design. Dual-extrusion 3D-printed prototypes are characterized by a custom testing apparatus using a 2.2 kN load cell at 25 mm/s over a 0–90° rotation range across six recorded load cycles to measure torque–angle curves and stiffness under large deformations. Angle-dependent stiffness is evaluated over three fixed intervals (0–30°, 30–60°, and 60–90°) to quantify multi-stage behavior. A 2-dimensional corotational frame model and a Simscape Multibody model, including a rolling-contact knee configuration, use the same parameterization to relate geometry, nonlinear mechanics, and system-level motion. Experiments and simulations show multi-stage torque–angle profiles and predictable stiffness modulation across all configurations, with both magnitude and transition angle tunable through Bézier class and active-link distribution, positioning the RCJ as a CAD/CAE-compatible joint architecture for assistive devices or wearable robotic systems and a basis for advancing functional biomimicry in compliant mechanism design.