Developing a prosthetic that is simultaneously durable, comfortable, lightweight, and cost-effective is an engineering challenge with very little margin for error. The Circleg One must meet strict mechanical standards — standards that govern real people's mobility and safety.
To achieve the above, we work with Ansys Mechanical structural simulation software. Simulation gives us the ability to evaluate structural performance, material behavior, and component flexibility before a single physical part is produced. This means we can identify weaknesses, refine designs, and validate solutions with precision — dramatically reducing development time and cost.
One of our most critical areas of focus is the knee joint. For above-knee amputees, the knee is central to gait, balance, and weight-bearing. Our finite element analysis work in Ansys Mechanical allowed us to model stress distribution across the knee component under load conditions that mirror real-world use — and to verify those models against physical testing.
Early in the process, we worked with simplified component models. As the product evolved, so did our simulations. By integrating material characteristics specific to our injection molding process, we were able to resolve discrepancies between simulated and measured results — and ultimately meet the strict mechanical requirements the Circleg One demands.
The Circleg One is built on circular economy principles. Because the system is modular, worn or damaged components can be swapped out without replacing the entire device. This approach also supports the infrastructure of local prosthetic care. By enabling orthopedic technicians to fit, adjust, and service the Circleg One with minimal tooling, we extend the reach of quality prosthetic care beyond centralized clinics and into the communities where it is needed most.
Every design decision at Circleg is made with one goal in mind: freedom of mobility for everyone. The Circleg One is the product of rigorous engineering, purposeful design, and a commitment to safety and high quality for all.
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