Design Optimization of a Handcycle Manual Wheelchair using the Design for Manufacture and Assembly (DFMA) Approach

Handcycles offer a good mobility option for people with lower limb disabilities, encouraging them to be more mobile and engaged in the community. However, the conventional handcycle designs are often characterized by the high manufacturing costs attributed to the higher number of components of the handcycle and complicated assembling processes. These are limitations that make them less affordable and accessible to people with lower limb disabilities. The purpose of this study is to design a Manual wheelchair handcycle to enhance its manufacturability through the Design for Manufacture and Assembly (DFMA) approach to reduce the manufacturing cost and assembly complexity. The handcycle idea was developed in Solid Works and analysed with the Boothroud-Dewhurst DFMA methodology. The optimization of the design involved reducing the number of parts and simplifying assembly tasks to ensure that the product could be manufactured at a lower cost without sacrificing its functionality. The optimized design reduced the total number of components from 81 to 35, decreased assembly labour time by 72.8%, increased the DFA index from 25.16% to 71.43%, reduced the manufacturing cost from RM1,417.38 to RM206.31, and lowered the product weight from 34.79 kg to 12.79 kg. The results demonstrate that the DFMA approach is an effective method for developing affordable, efficient, and user-friendly handcycle designs. This study provides a practical framework for optimizing the design of assistive mobility devices and supports the development of cost-effective products that enhance accessibility for wheelchair users.

Handcycle, Manual wheelchair, DFMA (Design for Manufacture and Assembly), Product optimization.

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