Mobility aid design & development, plays a vital role in helping people remain  independent, and able to lead fulfilling lives. But designing products for users with a wide range of physical and cognitive limitations requires more than good intentions, it requires a deep understanding of real-world needs and inclusive design from day one. 

Creating a mobility aid that is safe, intuitive, and manufacturable demands a structured, evidence-based development process. From early concept exploration through prototyping, engineering refinement, compliance testing, and full-scale production, each stage brings its own challenges and decisions that directly impact user safety and experience. 

This case study explores these stages, combining expertise in ergonomics, materials, standards, and engineering to take a mobility aid from an initial idea to a fully validated, production-ready product. 

End-to-End Mobility Product Development Process & Stages 

User Research, Requirements Definition & Concepts 

Mapping the user landscape and their needs through storyboards is a crucial first step in the development process. This early research helps uncover all the factors that must be considered, from ergonomic and safety requirements to more specialised needs such as clinical validation or smart features that enhance everyday function. 

By capturing real user behaviours, limitations, and scenarios, we can define clear requirements that guide concept development. This early clarity not only focuses the design team on the true problem to be solved but also reduces development risk by ensuring that every concept explored is grounded in real-world needs. 

Then you can move to exploring how best to solve the problem. Some concepts may be based on the physical parameters and constraints.  

As an example, for a walker assist project:  Our starting point was with the best practice height, and physical sizes and then we were able to oversketch the concept solutions. So, it started from  

• Mechanical layouts in CAD with exploration and ergonomic review 

• Load-path and leverage analysis. Electronic or UX interfaces. 

then we considered 

• Configuring controls for ease of use, both by the aid user, and by potential helpers - this required us to make the control configuration flexible and accessible even from the ground in case of a fall. The design of the controls also used familiar layouts taking inspiration from elevators and traffic lights. 

• Balancing keeping the aid compact and manoeuvrable to easily navigate through narrow aisles and doorways, vs making it wide enough to comfortably accommodate stockier users. We added some width adjustability and made it collapsible for storage.  

• Supporting users who may have frail bodies which injure easily. We adjusted supports to be broad flexible and soft to spread pressure across a wider area.  

• Adding grips, straps and wedges to help users with low motor function.  

• A focus on safe, easy clean materials, without areas for dirt to become trapped. 

Mobility Aid Prototyping 

Prototyping is essential for validating assumptions, mechanics, and real-world use.  

At Bang Creations, we build, test, and iterate to ensure every interaction works as intended. With larger support products, such as walkers and lifting aids, the challenge lies in using representative materials and mechanisms early enough to meaningfully evaluate function and user interaction. 

Using different types of prototypes to assess different aspects is the most effective approach: 

• Looks-like prototypes help evaluate form, ergonomics, grip comfort, and visual styling. 

• Works-like prototypes validate mechanical performance, load paths, and functional behaviour. These may take the form of simple rigs to test a single feature or full assemblies to test the entire system. 

Testing with users further refines usability, confirms correct adjustability, and ensures compatibility with existing mobility equipment.  

For our walker project, the working prototype acted as a demonstrator, allowing partners to interact with the product, generate potential order interest, and secure seed funding. 

At this stage, safety assessments are essential to verify compliance. It is also the ideal point to review target costings and identify suitable manufacturing methods and suppliers. 

Engineering for Manufacture 

Even after a prototype has been created, the design may not yet be production-ready. This stage focuses on detailed engineering, preparation for tooling, and bringing the product into manufacture. 

While many aspects are similar to standard product development, a key consideration for mobility aids is selecting suppliers experienced with similar equipment, ensuring they understand the required standards and quality levels. 

This phase typically includes: 

• Detailed mechanical engineering to resolve any outstanding prototype issues 

• Tolerance analysis and stress calculations, where necessary 

• Material and finish specification for both hard components and soft padding or textile parts 

• Design for Manufacture (DFM) and Design for Assembly (DFA), including repairability 

• Supplier identification and vetting, ensuring their Quality Management Systems (QMS) meet mobility equipment standards 

This stage ensures the final design is safe, reliable, and ready for large-scale production. It also marks the point where the design is released for tooling investment and part procurement. 

• Next steps involve tool trials and part approvals, followed by: 

• Production of a small batch for final testing, market seeding, and pilot feedback 

• Compliance and certification using the small batch product, including ISO strength and durability testing, hygiene and chemical resistance checks, sharp-edge and pinch-point assessments, stability evaluation, and any relevant medical regulations 

• RFQ processes, quality control, final compliance submissions, packaging, and finally shipping 

This structured approach ensures that every mobility aid entering production meets the highest standards of safety, reliability, and usability. 

At Bang Creations, we work closely with your manufacturing partners to ensure all mobility-aid safety requirements are met and that the product maintains its performance and reliability at scale. 

Ready to Develop Your Mobility Aid? 

With experience developing assistive devices such as wheelchair lift assist mechanisms, crutch holder attachments, and other mobility-support products, our team ensures your product is functional, user-centred, and ready for manufacture. 

Bring your idea to life with a proven team that understands the challenges of mobility product development. 

Speak to our team about your idea, prototype, or development challenge. 

Speak to Bang Creations → 

Back