Blatchford, a multi award-winning manufacturer in prosthetic technology, approached us to help develop Avior – a microprocessor-controlled knee designed for enhanced mobility, safety and adaptability for amputees around the world.
Working closely with the Blatchford team, we helped in a number of areas – from enclosure design and sealing strategies to materials, styling, prototyping and production readiness.
The result is a responsive prosthetic knee that balances biomechanical performance with durability, comfort and confidence for wearers.
Designing a wearable medical device like Avior means meeting technical, environmental and human demands which compete against each other.
Every gram mattered. We needed a prosthetic light enough for natural gait yet robust enough for everyday use. Simultaneously, the enclosure had to meet IP65 protection standards to safeguard the electronics from dust, water and contaminants. All within strict space and weight constraints.
Daily exposure to friction, impacts and chemicals (such as cleaning agents and bodily fluids) meant carefully engineered materials and finishes. Inside, precision was everything – complex internal mechanisms demanded exact packaging and tight tolerances as one misalignment could compromise the entire system.
The wearer experience required a sealed membrane control panel with intuitive feedback and straightforward charging integration. Commercially, this had to be manufacturable at scale making a solid supplier collaboration imperative to ensure feasibility and cost efficiency.
Form and function had to be built around the wearer so we began with a holistic review of the mechanical and environmental performance requirements. From the outset, we worked to balance structural integrity with lightweight engineering, using advanced materials to reinforce the enclosure without excess bulk.
The enclosure design demanded a carefully engineered multi-part housing that resists ingress whilst also maintaining accessibility for internal components. Achieving IP65 – given the weight, size and tolerance constraints – required an innovative combination of seal geometries, horizontal and vertical misalignment allowances, and fastening strategies to maintain protection without introducing stress points.
Working closely with suppliers, we helped identify materials that would provide the abrasion, chemical and impact resistance needed for everyday use. This included iterative testing against harsh conditions and fine-tuning surface textures and finishes to balance durability with a medical-grade aesthetic.
We supported the design of a sealed membrane interface panel to ensure clear tactile feedback while preventing ingress. The interface was carefully positioned for easy access and designed to integrate with the prosthetic’s smart control systems. We also collaborated on the magnetic charging integration for interaction without compromising protective requirements.
Throughout the process, we used rapid prototyping and close supplier collaboration to de-risk its manufacture at scale.
Avior represents the future of intelligent prosthetic mobility which combines biomechanical intelligence with real-world durability and thoughtful design.
For us, this project illustrates the power of close collaboration between researchers, industrial designers, engineers and clinical specialists.
By contributing across concept development, materials, enclosure engineering, user interaction and production support, we helped create a medical device that genuinely improves the lives of its wearers and evolves with them.
