DESIGNER CANE

Mobility aids like canes are invaluable tools that help individuals with walking abnormalities and balance issues or those recovering from surgery maintain their independence. For adults aged 65 and over, mobility devices are increasingly necessary, with one in four using a cane or walker to improve their mobility. However, many mobility aids lack the style, functionality, and design sophistication users desire.

A multinational personal care corporation recognized this gap and contracted Synectic to create a premium walking cane to “celebrate” aging while providing unmatched functionality and aesthetic appeal. The company came to us with a concept from a high-end industrial design house and tasked us with developing the cane from a mechanical and functional perspective. Initially, they wanted the device to support a 500-pound individual. They also wanted the cane to come with multiple interchangeable parts for the handle and tip, molded in a wide range of colors. Additionally, they requested that the cane be stable enough to stand on its own and retrievable without bending over. We leveraged our engineering expertise and manufacturing experience to tackle the project through the following:

• Performed competitive product research to establish baseline specifications.
• Worked extensively with the customer to establish realistic product specifications. As a result, we tailored the design to accommodate individuals recovering from hip or knee surgery and the aging population, reducing the weight capacity requirement from 500 to 250 pounds.
• Developed an overmolded handle with a metal insert to prevent bending under 250-pound loads while maintaining ergonomic comfort.
• Designed a quick-release button for the cane’s foot, enabling tool-free replacement.
  Integrated track ridges on the cane shaft to prevent buckling and slipping during use.
• Created a tripod foot capable of standing independently and retrievable without bending over.
• Researched lightweight, durable, and wear-resistant materials for the handle, shaft, and foot.
• Ensured materials were easy to clean and antimicrobial to meet hygiene standards.
• Partnered with Mack Molding to determine cost-effective production processes.
• Conducted Design for Manufacturing (DFM) and Design for Assembly (DFA) analysis to refine the design for high-volume manufacturing.
• Completed stress analysis using linear Finite Element Analysis (FEA) and an initial tolerance analysis.
• Undertook mechanical testing to verify robustness, durability, and performance against product specifications.
• Compiled a comprehensive bill of materials (BOM).
• Produced fully tolerance drawings.

The result was a manufacturable, premium walking cane that combined exceptional functionality with personalized style, redefining mobility aids for post-surgical and aging demographics. The completed design included a vibrant, customizable device with ergonomic, antimicrobial handles and stable tripod and peg foot options, all built for lightweight durability and tool-free interchangeability