Power Supply  Transformer for Active Hand Orthosis

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The intelligent Motion Mate orthosis from the start-up Powered Orthotics enables patients to perform controlled gripping movements again. Würth Elektronik developed a transformer specially tailored to the orthosis for this project.

Motion Mate is designed as an open glove orthosis for people with limited hand function, for example after a stroke or accident. Around 100 million people worldwide are affected, 550,000 of them in Germany alone. The system uses electric motors and cable pull mechanisms to actively close the fingers and—unlike many existing solutions—also actively open them. This enables controlled support of gripping movements based on the functional principle of natural tendons.

What the Active Glove Orthosis is All About

In contrast to many conventional orthoses, the development of Motion Mate focuses on low weight and user-friendly handling so that the wearer can put the device on independently. Batteries and actuators are housed in a separate belt pouch (1.43 lb), which means that the orthosis itself remains particularly light at just 5.6 oz. Depending on the user's degree of impairment, the system is controlled via movement signals. A control unit connected via Bluetooth can be attached to various parts of the body, such as the chin, elbow or opposite hand. The system can also be operated using a smartphone app or voice control.

Orthosis in the Prototype Stage

The intelligent, active orthosis from Powered Orthotics is currently in the prototype stage and is being further developed for long-term use in collaboration with test users and with the support of Würth Elektronik. Elbe Electronic GmbH is responsible for production.

"Loss of hand function is not only a medical symptom, but also a daily barrier to independence, dignity and participation in life," explained Ryan Alicea, Co-Founder and CEO at Powered Orthotics. "At Powered Orthotics, we are bridging the gap between people's needs and the realistic possibilities of existing solutions by developing Motion Mate: a 5.6 oz motorized hand orthosis that supports intuitive opening and closing in a wearable, convenient form. Our goal is simple: we want to give people the opportunity to do more for themselves, more often, and put control back where it belongs: in their own hands."

"The power supply for an orthosis has to meet very specific requirements," adds Guillermo Regidor, Design Engineer at Würth Elektronik, who is leading the design work for the project. "It has to be compact and efficient and at the same time meet the strictest safety standards of protection classes IEC 60601-1 and 1 MOPP (Means of Patient Protection). After all, the device is worn directly on the body."

Customized Transformer Compact And Safe

He continues: "A flyback transformer with an input voltage of 12 V to 15 V, an output voltage of 12 V and a current of 1.5 A was required. Our search for an off-the-shelf component quickly revealed that none of the available solutions exactly met our customer's requirements. The safety regulations in particular were a decisive factor. For this reason, we opted for a specially adapted new development."

The customized transformer measures just 0.85 in × 1.14 in × 0.47 in and weighs only 0.40 oz. It works with an efficiency of 98 percent and is optimized for automated mass production. In addition to this custom-made product, other components from Würth Elektronik are also used in the orthosis. Further development support includes tests in the Würth Elektronik laboratories in Waldenburg, for example to evaluate shock and vibration resistance as well as thermal shock resistance.

Series Production to Start in 2026

After the first prototype, 15 more units will be produced and tested in everyday life by users with corresponding hand impairments. The knowledge gained will then be incorporated into series production, which is scheduled to start in 2026.

"We are proud to be working with Powered Orthotics on the Motion-Mate hand orthosis," says Alexander Gerfer, CTO of the Würth Elektronik eiSos Group. "Startups often face technical challenges on their own, from power supply and safety to miniaturization and manufacturability. With our experience and customized solutions, we help turn the concept into a device that makes everyday tasks easier and promotes user independence. Motion Mate shows what is possible when innovative start-ups and industry experts work closely together to overcome challenges from start to finish."

Prof. Dr. Lorenzo Masia, Professor of Intelligent Bio-Robotic Systems at the Technical University of Munich, is acting as scientific mentor for the project.

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