Prof. Song Xu’s team develops mass customisation of breathable lightweight hip protectors for the elderly via automatic inverse design and 3D printing
20 Jun, 2025

The research team of Professor Song Xu has developed mass customisation of breathable lightweight hip protectors for the elderly via automatic inverse design and 3D printing. In partnership with The Hong Kong Research Institute of Textiles and Apparel (HKRITA), the invention has recently received international recognition at the 50th International Exhibition of Inventions Geneva, winning a Gold Medal.

Principal Investigator and Team Members:
Professor Song Xu, Mr. Mo Haoming, Dr. Ding Junhao, Mr. Hu Zongxin, Dr. Winston Ma Wai-shing, Dr. Qu Shuo, Dr. Ye Haitao (Department of Mechanical and Automation Engineering)
Professor Yang Yi-jian, Dr. Zheng Xiaoping (Department of Sports Science and Physical Education)

Project Title:
Mass Customisation of Breathable Lightweight Hip Protectors for the Elderly via Automatic Inverse Design and 3D Printing

Project Description:
Hip fractures pose the most serious fall-related threat to the elderly. Sadly, many elderly are reluctant to wear traditional hip protectors, which are often bulky, non-breathable, expensive, and have limited size availability.

The new breathable and lightweight hip protectors are designed specifically for the elderly using 3D-scan-based inverse design and AI-automated lattice generation. This approach enables the 3D printing of these protectors with an optimized lightweight structure, minimizing weight and cost while maximizing user comfort. They can be easily attached to pants, reducing the risk of hip fractures caused by falls. This breathable and lightweight design is particularly suitable for the elderly living in hot and humid regions.


Hip protector developed by the team


Credit: “Vibrant Hong Kong:Episode 90” by RTHK 香港電台 [Link to video] (21:08-23:14)

Read more: CUHK wins a record-breaking 34 awards at the 50th International Exhibition of Inventions Geneva | CUHK Communications and Public Relations Office