In daily exercise, sports-related injuries due to posture and other factors are inevitable. Knee sleeves can alleviate injury severity and prevent secondary damage from improper muscle protection. For sports enthusiasts, the protective efficacy is paramount. Nevertheless, conventional commercial knee sleeves frequently exhibit shortcomings such as inadequate functionality, uneven pressure distribution, poor performance of knee protection, and difficulty in combining the comfort and functionality of knee sleeves. To address these issues, this study developed a 3D human knee joint model, utilizing finite-element software to simulate pressure distribution, body surface displacements, and mechanical interactions between knee sleeves and the joint. Based on these simulations, the structure of the knee sleeve was optimized with a zoned design, ensuring both functionality and comfort. Compared with experimental knee sleeves revealed that the optimized, zoned design maintained protective capabilities while providing more even skin pressure distribution and comfort. In addition, it significantly reduced knee joint surface displacement during exercise, enhancing pressure stability. These findings were a valuable reference for knee sleeve design, ensuring functionality while maximizing wearer comfort.
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