Queen's Bio-Mechatronics Design Team — Design & Simulation
Queen's University
Our team is focused on improving the structural reliability and functional performance of our exoskeleton by redesigning and strengthening its connection components. Building on feedback from last year’s competition and recognizing the limitations of 3D-printed parts, we are remodelling key interfaces—such as the knee joints, ankle joints, and tightening mechanisms—to increase durability, enhance user mobility, and ensure compliance with ACE safety and mechanical requirements. As part of the structures subteam, my work centers on developing sturdier, more dependable connection parts that support smoother movement, safer load transfer, and greater resilience across all competition events.
• Improve joint alignment so the knee and ankle can move naturally during key obstacle tasks.
• Reduce failure points by reinforcing 3D-printed parts and minimizing stress concentrations.
• Increase modularity so connection parts can be replaced quickly without full disassembly.
• Refine attachment interfaces for a secure fit and faster don/doff without sacrificing strength.
Our design process begins with evaluating last year’s components, identifying bulk, inefficiencies, and attachment issues. We are focusing on refining each connection part to reduce weight, improve stability, and streamline don/doff by redesigning structures, supports, and fastening mechanisms before moving into detailed part-by-part development.
Ankle Joint
Refining the ankle joint to improve mobility, durability, and natural motion during obstacle tasks.
Our redesign of the ankle joint connection started with analyzing last year’s component to identify bulk, unnecessary material, and motion restrictions. The previous design limited natural ankle roll and created stress concentrations that led to brittle failures in 3D-printed parts. By reviewing the original CAD, we identified non-structural regions that could be removed or reshaped to reduce weight without compromising strength, while also smoothing transitions and optimizing wall thickness to prevent cracking.
We then refined the joint’s alignment and geometry to better support natural flexion and stability on uneven terrain. Adjusting the pivot location and modifying the interface allows smoother lateral movement and improved control during obstacle tasks. High-stress zones were also reinforced through targeted ribbing and material redistribution, ensuring the joint can withstand repeated loading while remaining lightweight and competition-ready.
Buckles & Strap System
Replacing the loop-through rubber strap with a faster, more secure quick-release system.
The buckle redesign began by evaluating the previous year’s strap system, which relied on a long rubber band that had to be manually looped through the connector and attached each time the suit was worn. This process was slow, inconsistent, and often required multiple adjustments to achieve the desired tension, giving up valuable time during don/doff and making performance less reliable. Additionally, the old rubber material felt loose and lacked the stiffness needed to maintain secure contact between the pilot and the suit during movement.
To address these issues, we transitioned to a quick-release buckle mechanism that allows the pilot to secure the connection in a single motion, significantly improving efficiency and repeatability. The new system pairs the buckle with a firmer, more durable strap material that maintains consistent tension and reduces unwanted movement between the pilot and the structure. By redesigning the attachment points to integrate the buckle cleanly into the connection geometry, the new system not only reduces don/doff time but also increases comfort, stability, and overall usability during competition.
