Medical Product & Ergonomic Keyboard Design

Human-factors-driven clinical keyboard redesign developed to improve wrist posture, reduce physical loading, and increase comfort during extended clinical use.

Project Description

KS Projects redesigned a clinical macro keyboard for healthcare professionals working extended shifts, with a focus on ergonomics, comfort, control accessibility, and acoustic performance.

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Using human factors engineering, anthropometric hand data, pressure mapping, and rapid prototyping, the keyboard chassis and control layout were redesigned around natural hand and wrist positions.

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95th-percentile hand data and finger-reach studies were used to establish optimal key zones. Multiple 3D-printed prototypes were produced to evaluate grip, reach, wrist position, and contact pressure.

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A 9° negative tilt and split key zones were introduced to support a more neutral wrist posture.

The thumb-control cluster incorporates four hotkeys and a joystick positioned on a 15° angled surface, reducing excessive thumb extension during repeated use.

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A two-piece aluminum chassis with gasket mounting, PORON dampers, and internal structural ribs was developed to reduce vibration and operating noise.

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Engineering Capabilities

• Ergonomic CAD Surfacing – Organic key zones and contoured palm supports

• Anthropometric Analysis – Hand dimensions and finger-reach studies

• Rapid Prototyping – SLA prototypes for physical evaluation

• Pressure Mapping – FlexiForce sensor testing

• Human Factors Engineering – Wrist, hand, and thumb positioning

• Vibration & Acoustic Engineering – Gasket mounting and damping

• Material Engineering – TPU palm supports, aluminum chassis, and engineered key components

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Project Results

✅ Measured carpal load reduced by 41% compared with the reference flat keyboard

✅ Pilot testing showed an additional 2.3 hours before reported discomfort

✅ Operating acoustic level maintained below 45 dB

✅ Internal chassis engineering reduced sound by approximately 12 dB

✅ Modular palm supports allow rapid configuration changes

✅ Produced a 30-page ergonomic engineering report and ISO 9241-410 compliance checklist

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Technologies & Expertise

Human Factors Engineering | Medical Product Design | Ergonomic Product Design | Anthropometrics | SolidWorks | CAD Surfacing | SLA Prototyping | Pressure Mapping | Acoustic Engineering