Neurobypass 1.0: A Mechanical Approach on 3D-Printed Neurocontrolled Hand Orthosis for Subacute Post-Stroke Rehabilitation

Abstract

Stroke is one of the leading causes of motor disability worldwide, directly impairing limb functionality and compromising individuals’ independence in daily activities. Stroke‐induced hand paresis requires assistive devices whose kinematics, compliance, and morphology faithfully emulate healthy biomechanics. Neurobypass 1.0, under SENAI CIMATEC’s ReaPTA 5.0 programme, delivers a patient-personalized hand orthosis neuro-controlled by EEG that is engineered around three mechanical pillars: biomimicry, human-like motion and additive manufacturing. The technology integrates electroencephalography (EEG) to command robotic elements via recognition of neural motor-intention patterns, additive manufacturing with flexible and rigid materials (TPU/PLA) and an immersive virtual-reality environment, delivering neurofeedback that stimulates neuroplasticity. By fusing brain-computer-interface (BCI), multi-material 3D printing, modular biomimetic geometry and minimum jerk kinematics into a single, low-cost platform tht amplifies the therapeutic impact alongside conventional therapy, providing clinicians with an evidence-driven, easily serviceable device to accelerate upper-limb functional recovery in post-stroke patients.