Design and Development of a Low-Cost Upper Limb Exoskeleton for Rehabilitation and Strength Augmentation

This paper presents the design and development of an untethered, powered exoskeleton system for upper limbs intended for rehabilitation, therapeutic applications, and occupational strength augmentation. Existing commercial exoskeletons are often bulky, expensive, and limited by tethered configurations. The proposed solution offers a low-cost, ergonomic, and wireless design actuated via onboard sensors and button-based control. The system is capable of collecting kinematic data to aid physical therapy through progress tracking. A 12V actuator-based mechanism assists in lifting tasks beyond normal human capacity. The mechanical frame uses lightweight aluminium alloy, optimized for strength-to-weight ratio, and is backpack-mounted for portability. Experimental validation confirms successful lifting of 20 kg payloads and system responsiveness under 100 ms. Future improvements include integration of EMG-based control and adaptive torque modulation. This work aims to bridge the gap between affordable assistive robotics and practical human–machine integration for rehabilitation and industrial use cases.