Innovative 3D-Printed Hip Protection System

This research project aims to develop a next-generation hip protector insert for hip protector pants that is more hygienic, discreet, and wearable than current market options. Traditional foam-based insert/protectors are often bulky, uncomfortable, and visually unappealing; factors that reduce user compliance, especially among older cognitive adults. Our goal is to find a design for a pant insert that’s slim, low-profile and uses advanced 3D printing (FDM) with flexible materials, such as TPU, to create a lightweight structure that better manages impact forces from falls. Unlike conventional solutions, our design focuses equally on performance, comfort, and aesthetics, key factors for encouraging everyday use. The insert will undergo rigorous impact testing (drop tower) to validate its effectiveness under real-world fall conditions. Consistency and quality in manufacturing will be central, ensuring a scalable, high-performing product. For the partner organization, this project presents an opportunity to bring a truly innovative product to market, one that responds to a critical need with a modern solution. By combining biomechanical insight with additive manufacturing, we aim to position this product as a leading option in personal fall protection, ultimately supporting injury prevention, healthcare cost reduction, and improved quality of life for vulnerable populations.

Faculty Supervisor:

Jonathan Laumer

Student:

Partner:

ON Trend

Discipline:

Engineering

Sector:

Manufacturing

University:

Okanagan College

Program: