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Bioinspired Design of Ergonomic Tool Handles Using 3D-Printed Cellular Metamaterials.

Gregor Harih1, Vasja Plesec1

  • 1Laboratory for Integrated Product Development and CAD, Faculty of Mechanical Engineering, University of Maribor, Slovenia Smetanova ulica 17, 2000 Maribor, Slovenia.

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Summary
This summary is machine-generated.

3D-printed gyroid metamaterial tool handles offer improved comfort by reducing peak pressures. Medium-stiffness designs provide the best balance of pressure redistribution and grip stability for users.

Keywords:
3D printingbioinspired designcellular metamaterialsfinite element methodproduct ergonomicstool handleuser comfort

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Area of Science:

  • Materials Science
  • Biomechanics
  • Ergonomics

Background:

  • Conventional tool handles made of stiff materials can cause discomfort and uneven pressure distribution.
  • Ergonomic tool handle design is critical for user comfort and task performance.

Purpose of the Study:

  • To investigate the use of 3D-printed cellular metamaterials with tunable stiffness for enhancing tool handle ergonomics.
  • To evaluate the impact of gyroid structure infill density on pressure distribution and user comfort.

Main Methods:

  • Finite element analysis (FEA) was used to simulate finger-handle interactions.
  • Subjective comfort evaluations were conducted with participants using 3D-printed handles with varying gyroid infill densities and a rigid handle.

Main Results:

  • Medium-stiffness gyroid handles significantly reduced peak contact pressures and improved pressure uniformity compared to rigid handles.
  • The softest handles showed excessive deformation, potentially compromising grip stability.
  • Subjective ratings indicated highest comfort for medium-stiffness handles, balancing fit, force transmission, and overall comfort.

Conclusions:

  • 3D-printed cellular metamaterials with tunable stiffness can enhance tool handle ergonomics.
  • A plateau-like mechanical response, bioinspired by human soft tissue, effectively balances pressure redistribution and grip stability.
  • This bioinspired design approach offers a promising avenue for developing user-centered tools that reduce fatigue and discomfort.