Designed around the arm.
BeeFlex upper-arm enclosure
A protective enclosure that gives a passive arm-support mechanism a wearable form. My focus was the upper-arm shell, from requirements and concepts to a printed part fitted into the team assembly.
My part of the product
BeeFlex was a team concept for passive upper-limb assistance using a gas-spring mechanism. I designed the non-load-bearing upper-arm enclosure. Its job was to conceal the structural frame, provide a comfortable interface and leave enough clearance for the joint to move.
Choosing the enclosure
I compared three concepts against appearance, comfort, manufacturability, assembly and joint clearance. A tapered enclosure with integrated strap features scored 4.65 out of 5 in the weighted concept assessment. It offered a less bulky form while retaining access to the mechanism.
From surfaces to assembly
I developed the enclosure parametrically in Siemens NX, adding rounded edges, fastening bosses and clearance around the frame. Section views and orthographic drawings communicated the internal geometry. Assembly checks helped position the shell without obstructing elbow movement.
A part I could hold and fit
I manufactured the prototype in black PLA on my Bambu Lab X1 Carbon. Print orientation, support placement and the surfaces touching the user all influenced preparation. Physical assembly allowed me to inspect fit, fastening access and joint clearance against the CAD design.
Design reflection
The result is an enclosure and assembly prototype, with renders exploring finish and colour. It demonstrates product development and manufacturing judgement. Sustained comfort, assistance performance and any reduction in physical strain would require a separate user-testing programme.
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My upper-arm enclosure, shown as a standalone product render.
Project evidence: BeeFlex individual design portfolio dated 2 February 2026, original renders, CAD views and prototype photographs. The complete assistive system is team work; the upper-arm enclosure is my documented contribution.
A second life for the package.