Designing Customized Wearable Devices: A Novel AI-Based Framework for Product Development

Abstract

The development of personalized wearable devices, including orthopedic products, requires individual customization to ensure user satisfaction and sustained usage over time. Recent advances in image-generative Artificial Intelligence (AI), such as DALL-E from ChatGPT, have shown promise for creating individualized designs tailored to user preferences. However, the structured integration of such AI tools into broader iterative product development workflows (including 3D-modeling, personalization, and physical manufacturing) remains largely unexplored in this application context. This work presents a user-centered design process that incorporates image-based generation into early design phases to address both functional and aesthetic user needs. A case study was conducted to demonstrate the process, resulting in the design and fabrication of a customized foot orthosis using additive manufacturing. To assess the design outcome, the prototype was evaluated through a subjective user questionnaire and supplemented by qualitative feedback from an orthopedic professional. The results highlight both strengths and limitations of AI-assisted workflows in personalized product design. Overall, the findings illustrate how AI can be effectively embedded in user-centered design processes and provide implications for applications beyond orthopedic footwear design.

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