A Hybrid Anchoring Technology Composed of Reinforced Flexible Shells for a Knee Unloading Exosuit

Soft robotic wearables have emerged as an ergonomic alternative to rigid robotic wearables, commonly utilizing tension-based actuation systems. However, their soft structure's natural tendency to buckle limits their use for compression bearing applications. This study presents reinforced flexible shell (RFS) anchoring, a compliant, low-profile, ergonomic wearable platform capable of high compression resistance. RFS anchors are fabricated with soft and semirigid materials that typically buckle under compressive loads. Buckling is overcome using the wearer's leg as a support structure, reinforcing the shells with straps, and minimizing the space between the shells and the wearer's skin—enabling force transmission orders of magnitude larger. RFS anchoring performance was evaluated comparatively by examining the shift-deformation profiles of three identically designed braces fabricated with different materials: rigid, strapped RFS, and unstrapped RFS. The unstrapped RFS severely deformed before 200 N of force could be applied. The strapped RFS successfully supported 200 N of force and exhibited a nearly identical transient shift-deformation profile with the rigid brace condition. RFS anchoring technology was applied to a compression-resistant hybrid exosuit, Exo-Unloader, for knee osteoarthritis. Exo-Unloader utilizes a tendon-driven linear sliding actuation system that unloads the medial and lateral compartments of the knee. Exo-Unloader can deliver 200 N of unloading force without deforming, as indicted by its similar transient shift-deformation profile with a rigid unloader baseline. Although rigid braces effectively withstand and transmit high compressive loads, they lack compliance; RFS anchoring technology expands the application of soft and flexible materials to compression-based wearable assistive systems.