Hip Device Build Guide

STRUCTURE

Important Note:

The build guide assumes you have already fabricated the PCB. For instructions on how to do so, see the Electrical Section.

The contents of the build guide are ordered sequentially. We advised you to move through the build in the order presented. However, jumping around is also fine if it better suits you; just be aware that references may be made to components you have not yet made.

The build guide begins here, with a list of required tools and equipment (Note: the Bill of Materials goes into detail of the materials required). If any of the hyperlinks do not work, please notify us at theopenexo@gmail.com.

The build guide then moves to fabrication, where details on how to print and machine the parts needed for the device. From there the guide moves into the mechanical and electrical assembly. Note that regarding the electrical assembly, the PCB is assumed to have already been fabricated. For documentation on doing so, refer to CAN Motor PCB in the Electrical Section. 

PARTS/MATERIALS REQUIRED

This build contains 3D printed parts, machined carbon fiber and aluminum parts, a prefabricated hip belt, and various electrical components including motors, wiring, and a custom printed circuit board. A bill of materials (BOM) is provided which outlines all the necessary materials and fasteners (tools not included, see below) and where each can be purchased.

Worth noting in the BOM are the carbon fiber plates and tubing. These materials do not need to be purchased directly if you wish to have a third party manufacture them for you. In our case, we manufactured these components ourselves. If you would like your own tools for fully manufacturing all the components, you will need a CNC, a drill press, and a Dremel.

Also worth noting are the three items under “Externally Manufactured Parts” in the BOM. These include aluminum adduction/abduction blocks (made of 7075 aluminum), which allow for ad/abduction motion of the legs, as well as a custom PCB used to control the exo. Further information for these components can be found in Machined Aluminum and CF and CAN Motor PCB, respectively.

TOOLS REQUIRED

PPE

For certain portions of this build, adequate personal protective equipment (PPE) will be necessary. Below is a list of the minimum required PPE.

1. Safety glasses

2. Respirator with P100 Filters (for machining carbon fiber)

3. Long sleeve shirt (for working with carbon fiber)

4. Ear protection (earmuffs or earplugs)

5. Heat resistant gloves (for thermoforming)

General Tools

Below are the tools used during the build process. The tools used for each step of the build are also listed in their respective sections.

1. Metric nut driver set

2. Metric hex keys

3. Torx drivers

4. Drill or drill press with drill bits 

5. A set of files or sandpaper

6. Dremel with cutting disks

7. Tile saw (a table saw, circular saw, or jig saw also works) – for cutting carbon fiber

8. Duct tape

9. Scissors

10. CNC (optional if parts are externally manufactured)

Tools for Electrical Components

1. Soldering iron

2. Solder

3. Heat gun

4. Wire stripper

5. Wire cutter

6. Utility knife

7. Crimping Tool

8. Helping Hands

9. Tweezers