Expandable Size-Changing Leg Mannequin Development
Advanced wearable pressure monitoring system with 64 sensors for biomechanical analysis through garment integration
Overview
An innovative expandable leg mannequin system developed for a UK university research project, featuring 64 integrated pressure sensors to monitor bone and outer pressure distribution through wearable garments. This sophisticated biomechanical analysis system provides real-time pressure mapping and data visualization, enabling researchers to study the effects of compression garments, prosthetics, and orthotic devices on lower limb biomechanics. The system combines mechanical engineering with advanced sensor technology to create an adjustable mannequin that can simulate various leg sizes and shapes while maintaining precise pressure measurement capabilities.
Key features
- 64 high-precision pressure sensors strategically positioned across the leg surface
- Expandable mechanical design allowing size adjustment from XS to XL
- Real-time pressure mapping with color-coded visualization
- Multi-zone pressure analysis for different leg regions (calf, shin, thigh, ankle)
- Wireless data transmission for untethered testing
- Custom data acquisition system with high sampling rate (100Hz+)
- Integration with garment testing protocols for compression wear validation
- Calibrated pressure range suitable for medical and sports applications
- Durable construction for repeated testing cycles
- Software dashboard for data analysis and export
From challenge to solution
Challenge
Our solution
Maintaining sensor accuracy across different mannequin sizes and expansion states
Implemented flexible sensor mounting system that maintains contact during expansion
Ensuring consistent sensor contact pressure during size changes
Developed multi-point calibration algorithm accounting for curvature and size variations
Managing 64 sensor channels with minimal crosstalk and interference
Designed custom multiplexing circuit with isolated channels for clean signal acquisition
Creating a mechanical design that expands uniformly while preserving anatomical shape
Created segmented expansion mechanism with synchronized actuators for uniform scaling
Developing calibration procedures for pressure sensors on curved surfaces
Built automated calibration routine using reference pressure standards
Results & impact
- Successfully deployed in UK university biomechanics research laboratory
- Enabled testing of 50+ different compression garment designs
- Provided quantitative pressure data for medical device validation
- Reduced garment testing time by 60% compared to human subject trials
- Published research findings based on system data in peer-reviewed journals
Specifications
- Sensor Count
- 64 pressure sensors
- Pressure Range
- 0-200 kPa
- Accuracy
- ±2% full scale
- Sampling Rate
- 100 Hz per channel
- Size Range
- XS to XL (adjustable)
- Data Interface
- Wireless + USB
- Battery Life
- 8+ hours continuous
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