Smart orthoses hold great potential for intelligent rehabilitation monitoring and training. However, most of these electronic assistive devices are typically too difficult for daily use and challenging to modify to accommodate variations in body shape and medical needs. For existing clinicians, the customization pipeline of these smart devices imposes significant learning costs. This paper introduces ThermoFit, an end-to-end design and fabrication pipeline for thermoforming smart orthoses that adheres to the clinically accepted procedure. ThermoFit enables the shapes and electronics positions of smart orthoses to conform to bodies and allows rapid iteration by integrating low-cost Low-Temperature Thermoplastics (LTTPs) with custom metamaterial structures and electronic components. Specifically, three types of metamaterial structures are used in LTTPs to reduce the wrinkles caused by the thermoforming process and to permit component position adjustment and joint movement. A design tool prototype aids in generating metamaterial patterns and optimizing component placement and circuit routing. Three applications show that ThermoFit can be shaped on bodies to different wearables. Finally, a hands-on study with a clinician verifies the user-friendliness of thermoforming smart orthosis, and technical evaluations demonstrate fabrication efficiency and electronic continuity.

Snap-through instability, like the rapid closure of the Venus flytrap, is gaining attention in robotics and HCI. It offers rapid shape reconfiguration, self-sensing, actuation, and enhanced haptic feedback. However, conventional snap-through structures face limitations in fabrication efficiency, scale, and tunability. We introduce SnapInflatables, enabling safe, multi-scale interaction with adjustable sensitivity and force reactions, utilizing the snap-through instability of inflatables. We designed six types of heat-sealing structures enabling versatile snap-through passive motion of inflatables with diverse reaction and trigger directions. A block structure enables ultra-sensitive states for rapid energy release and force amplification. The motion range is facilitated by geometry parameters, while force feedback properties are tunable through internal pressure settings. Based on experiments, we developed a design tool for creating desired inflatable snap-through shapes and motions, offering previews and inflation simulations. Example applications, including a self-locking medical stretcher, interactive animals, a bounce button, and a large-scale light demonstrate enhanced passive interaction with inflatables.

Access to computer-aided fabrication tools, such as 3D printing, empowers various craft techniques to democratize the creation of artifacts. To afford new blow molding techniques in the field of Human-Computer Interaction, we make efforts to simplify this challenging handy fabrication and enrich the design space of blow molding by taking advantage of the thermoformability and heat deformability of 3D printed thermoplastics. We propose a novel and democratized blow molding technique, PneuFab, enabled by FDM 3D-printed custom structures and temporal triggering methods. Then we implement and evaluate a design tool that allows users to play with parameters and preview the resulting forms until achieving their desired shapes. Showcasing design spaces including artifacts with complex geometries and tunable stiffness, we hope to expand access and dive into what more the digital blow molding fabrication can be.

The field of Human-Computer-Interaction (HCI) has been consistently utilizing kinematic mechanisms to create tangible dynamic interfaces and objects. However, the design and fabrication of these mechanisms are challenging due to complex spatial structures, step-by-step assembly processes, and unstable joint connections resulting from the inevitable matching errors within separated parts. In this paper, we propose an integrated fabrication method for one-step FDM 3D printing (FDM3DP) kinematic mechanisms to create dynamic objects without additional post-processing. We describe the Arch-printing and Support-bridges method, which we call All-in-One Print, that compiles given arbitrary solid 3D models into printable kinematic models as G-Code for FDM3DP. To expand the design space, we investigate a series of motion structures (e.g., rotate, slide, and screw) with multi-stabilities and develop a design tool to help users quickly design such dynamic objects. We also demonstrate various application cases, including physical interfaces, toys with interactive aesthetics and daily items with internalized functions.

Biomimicry, a methodology adapted from nature, always inspires optimum solutions and innovative technologies in human history. To get children interested in, excited about, and inspired by biomimicry, we introduce KiPneu, a robotic platform that facilitates biomimicry education through hands-on, solution-oriented learning and a digital learning environment. KiPneu allows children to mimic flexible animal locomotion, like fish swimming or worm squirming, using low-cost building blocks and non-electrical pneumatic actuators. We provide five types of non-electrical tangible valves to adjust robot motion characteristics, such as direction and speed, through engaging tangible programming. Additionally, to facilitate the whole learning process, KiPneu comes with interactive instructional interface that visualize and simulate the pneumatic system. To validate KiPneu’s educational efficacy, we conducted a three-day workshop with 21 children aged 5-12. Pre-and-post surveys revealed KiPneu not only enhanced their understanding of animal locomotion mechanisms but also spurred interest in creative construction using acquired knowledge.

Orthoses with electronic functions have emerged as a promising medical product in response to the increasing demand for rehabilitation training, therapy assistance, and health monitoring. However, fabricating this “smart orthosis” often requires long development cycles and exorbitant prices. We introduce E-Orthosis, an integrated fabrication approach with construction toolkits for healthcare professionals to quickly embed electronics in off-the-shelf orthoses with customized functions cost-effectively and time-efficiently. Specifically, we develop components with magnets and pogo pins to support rapid attachment and sustainable use, and textile-based electrodes with snap installation to improve the wearing experience. We also provide a circuit iron tool to apply circuit traces on complex surfaces of orthoses directly and a hot punch tool to embed magnet ports and electrodes. Three application examples, technical evaluations, and expert reviews demonstrate the functionality of E-Orthosis and the potential for democratizing rapid-developed and low-cost smart orthoses for patients.