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Wearable robots that assist paraplegia patients should be manufactured according to the shape of the individual wearer. With the development of advanced three-dimensional (3D) printing technologies, such customizations are becoming available. However, conventional 3D printing customization requires extensive template remodeling, which is non-productive and inefficient. This study proposes a 3D-printed (3DP) physical human–robot interface (pHRI) based on a sizing system that facilitates customization to body shapes. The proposed system is a pre-developed pHRI in various sizes and shapes using a human body shape database. Conformity of shapes and dimensions were evaluated visually via shape deviation analysis for 10 persons having paraplegia. With the proposed 3DP-pHRI, the trunk comprised 18 sections and the shank comprised nine. A biased trend of coverage rates in the shank 3DP-pHRI size system was identified. The trunk and shank subsystems were found to be adequate in terms of shapes and dimensions, with values within the mean deviation range of ±10 mm. A novel 3DP-pHRI size system facilitating customization tool for fabricating wearable robots for paraplegia patients according to body shape was developed, and its effectiveness was assured. The new system can be used for various wearable robot pHRIs, and the database is expected to supply a comprehensive pHRI template library.

A 3D Printed Physical Human–Robot Interface Based on a Sizing System to Facilitate Customization: Wearable Robots for Paraplegia