FlexiFit

THE PROBLEM

Ankle sprains are among the most common and recurrent lower-extremity injuries in sports, accounting for 16%-40% of sports-related injuries. Of these cases, up to 40% of athletes develop chronic symptoms such as pain, swelling, and instability that can persist for at least 12 months post-injury. These lingering effects can lead to severe psychological impacts, including heightened anger, depression, anxiety, and trauma-like symptoms, with 23%-45% of athletes reporting fear of re-injury as their primary source of anxiety. Despite advancements in rehabilitation, the risk of re-injury remains a serious concern, often hindering athletes from returning to peak performance and, in some cases, ending their careers prematurely.

“There’s a real fear—fear of being tackled again or not
being able to perform at the same level. This fear can
make you hold back, which actually increases the risk
of re-injury because you’re bracing and guarding the
injured area, putting it in an unnatural position.”
interview participant 1

RESEARCH SUMMARY

Research revealed that recurrent ankle injuries are common among athletes, with multiple contributing factors identified through both primary and secondary sources. Muscle weakness, insufficient preventive strategies, and inadequate rehabilitation significantly impact athletes’ recovery post-injury. Many participants reported chronic pain, reduced mobility, and lingering muscle weakness, suggesting that initial injuries often remain unresolved.

This aligns with secondary research findings showing that initial ankle sprains can damage mechanoreceptors around the joint, potentially causing long-term proprioceptive deficits that increase reinjury risk. Despite acknowledging the importance of prevention, athletes showed a marked decline in preventive measures after reinjury, often relying on strapping tape due to its affordability and convenience. This preference underscores a gap in the availability of more durable, comprehensive preventive solutions.

Final product concept

FlexiFit is an ankle stabilising device that provides tailored support to the different recovery stages that an athlete experiences. Through 3D scanning technology, flexifit is customised to the users own body to ensure an optimal fit. It’s designed as a sleek, low-profile ankle brace integrated into a compression-style sock that allows users the benefits of both stability and convenience. This unique design addresses the need for discreet, all-in-one support without the need for multiple layers.

A dial tightening mechanism is incorporated into the back of the product which allows the user to adjust the tension and support of the device by providing an adaptive support system. This consists of a dial-adjusted ratchet and pawl system that allows users to increase or decrease tension based on their needs. The mechanism provides easy adjustments with a quick-release feature, ensuring the brace can adapt to different activities and levels of support and can be detached from the rear of the ankle for additional comfort and optimal wear during sporting activities. These features are key to helping athletes find their ideal level of stability on the field or during recovery.

Design and features

Customised fit and enhanced comfort

FlexiFit employs advanced 3D scanning technology to create a precise, individualised fit, optimising support for each user’s unique anatomy. The design integrates seamlessly into a low-profile, compression-style sock, ensuring stability with a sleek, unobtrusive appearance suitable for high-performance use.

Adaptive tension control mechanism

Featuring an innovative dial-adjusted ratchet and pawl system, FlexiFit enables precise adjustments to tension, accommodating varying activity levels and stages of recovery. The quick-release functionality allows for rapid tension adjustments, enhancing ease of use during athletic activities and recovery.

User-friendly visual guidance

Intuitive visual indicators on the dial guide users in achieving the correct level of support, simplifying the adjustment process and maximising functional ease.

Premium Materials for Durability and Performance

Constructed with TPU for the main structure and rear components to provide both flexibility and support, reinforced by carbon-filled nylon side supports for targeted stability in high-impact areas. The tensioning dial is made with polycarbonate and stainless steel, ensuring longevity and resilience.

Modular, Sustainable Construction

The modular design supports easy part replacements, extending the product’s lifecycle and contributing to a sustainable approach by reducing waste over time.

Multi-stage recovery support

FlexiFit offers adaptable support tailored to each stage of recovery and performance, addressing both physical and psychological aspects of rehabilitation. This ensures athletes return to activity with confidence and minimised re-injury risk.

Product demonstration video

Functionality

Design Impact

FlexiFit addresses key concerns that were discovered within the primary and secondary research throughout the project, decreasing the risk of ankle re-injury and increasing confidence in users when returning to sport. The seamless integration into a compression sock offers greater comfort than conventional braces, and the modular construction means that components can be replaced if needed, extending the product’s life cycle and reducing waste. This versatile design suits both intense sports and recovery scenarios.

FlexiFit represents an evolution in ankle support solutions, combining comfort, adjustability, and durability in a single product. By addressing both physical support and psychological confidence, FlexiFit empowers athletes to perform at their best while minimising the risk of re-injury. With FlexiFit, we are not just creating an ankle brace; we are building a comprehensive support system that adapts to every stage of an athlete’s journey, from recovery to peak performance.