Our design goals included light weight, ease of applying/removing, and no restriction of joint movement or visibility of the healing wound site. We also hoped to make it easier to apply a cold pack, and if possible, monitor the use of that as well.
Our brilliant apparel consultant, LaJean Lawson, came up with a lightweight harness that strapped to the thigh and calf, leaving the knee exposed. The electronics are hidden within the “smart buckles” that fasten the harness. This was my first experience designing an enclosure that progressed all the way to injection molding. The electronic design using a Bluetooth module and accelerometer sensors was more straightforward, but sensors to monitor the wearing of the device itself and application of the cold pack required some novel ideas. The US Patent Office agreed, finally issuing a patent in 2021 (3 years is par for that course).