Knee Brace Device Solution

Category: Production Setup & Tooling
Rationalising tooling, component manufacturability and overall ease of assembly for complex project 

De Royal, a U.S. Medical Device company specialising in Surgery, Wound Care and Orthopaedics approached us to redesign, develop and manufacture their Warrior Post-operative Knee Brace.

This product reinvigorated DeRoyal’s product range and strengthened its IP portfolio, putting the company back to a leading position in this highly competitive market. The Warrior Post-operative Knee Brace is a high performance orthopaedic support used in intensive knee treatments including total knee replacement.

The Product

The product was designed and developed to respond to the rigorous requirements of both clinicians and professional buyers. The resultant end product conveys De Royal brand values of high quality and deep understanding of the patient needs.

The key to the success of the new product was the intuitive and accurate ROM (Range of Motion) dial and push button height adjusters which Synecco proposed, designed and developed. This resultant product is easy to fit, offers a wide range of motion and is supportive and controllable enough to ensure the safe and progressive rehabilitation of patients.

The Process

Following patent whitespace analysis and defining the key elements required of the new product, extensive use of prototypes, crude mock-up, test jigs and real world testing was undertaken in-house. Synecco discovered that the key to success was to design robustness into an assembly with a complex array of adjustments, while rationalising the tooling, component manufacturability and overall ease of assembly.

The Result

The extensive risk-managed approach optimised production costs for our client. By combining our significant expertise right through to production set up and tooling together with our plastics expertise, we ensured the product was novel, robust and cost effective. The product is now a market leader for De Royal.