Contact person: Custom Soft Rib Flare Brace Design - Prototype Development & Production

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Location: Natal, Brazil

Budget: Recommended by industry experts

Time to start: As soon as possible

Project description:
"I need an experienced medical device manufacturer or specialist in chest deformities to prototype and produce a custom soft brace for rib flare correction based on specific technical requirements.
Project Concept:
This project aims to create a miniaturized, soft version of traditional rigid rib flare orthoses (like this one: [login to view URL]). The goal is to maintain therapeutic effectiveness while achieving maximum discretion and comfort.

Critical Design Understanding:
This is NOT a rib belt/binder. The biggest mistake people make is trying to use rib belts/binders to treat their Rib Flare deformities. These are meant for bruised and fractured ribs and apply concentric pressure to the body, which applies sideways force as much as front-to-back force. This sideways pressure can encourage the lower ribs to move medial (towards the middle) and anterior (forwards), thereby making the problem worse.

Biomechanical Requirements:
This device must apply anteroposterior (front-to-back) pressure specifically, which pushes the flaring ribs back into the rib cage, thus reducing the amount of flare. The design requires targeted, localized pressure points rather than circumferential compression.
Technical Specifications Required:

Maximum thickness: Under 10mm at thickest points (vs 20-30mm typical rigid braces)
Modular design with plastic connector plates and adjustable tension system
Targeted pressure application (NOT circumferential compression)
Materials: Medical-grade neoprene (4mm thickness), high-strength elastic bands, plastic connectors
Fastening system: Hook and loop (Velcro) attachments
Target: Invisible profile under regular clothing

Available References:

Complete product images showing all components and assembly
Detailed component breakdown photos
Original design specifications demonstrating proper pressure application
Reference to existing rigid orthoses for comparison

REQUIRED: Please include in your proposal:

Specific ideas on how to achieve this miniaturization while maintaining therapeutic effectiveness. Consider:

Alternative materials that provide firm support in thin profiles
Innovative fastening mechanisms for precise pressure control
Methods to distribute force effectively across smaller contact areas
Solutions for maintaining adjustability in a compact design


Design modifications or improvements you would recommend based on your expertise. If you see any potential issues with the current specifications or have suggestions for better approaches, please include them.
Prototype development plan including materials sourcing, manufacturing approach, and testing methodology.

Deliverables:

Technical drawings and 3D models based on reference images
Biomechanical analysis of pressure distribution
Material specifications and sourcing recommendations
Functional product (1 unit)
Assembly instructions with pressure application guidelines
Production feasibility assessment

Preferred Experience:

Medical device manufacturing and prototyping
Understanding of rib cage biomechanics and pressure applications
Orthotic/prosthetic design and production experience
Experience with miniaturization of medical devices" (client-provided description)