DIY Hands-Free Crutch – iWALK 2 Inspired

This is my homemade version of the iWALK 2 hands-free crutch, designed completely from scratch using only photographs of the original product as a reference.

The goal was to create a functional alternative using 3D-printed parts and commonly available aluminum tubes.

Design and Construction

Most of the components are 3D printed, but the assembly also requires aluminum tubes with diameters of 20 mm and 32 mm, along with some additional hardware.

I have included STEP files so you can easily modify the design to fit locally available tubing if the dimensions differ.

The design has no built-in height adjustment mechanisms. Instead, it is adapted to the user's height by cutting the aluminum tubes to the required lengths.

The 3D-printed components themselves are universal and can be used for different heights and for either the left or right leg.

You will also need to make your own fastening straps. I've included 3D models of the strap tensioners and locking components to help with this.

Real-World Testing

This is not just a concept or an untested prototype!

I personally used this crutch for approximately two months during my recovery, and it worked well for me.

After I no longer needed it, I passed it on to another person. We simply shortened some of the aluminum tubes to fit his height, and he is now happily using it too!

Files Included

• 3D-printable components
• STEP models for modification and customization
• Strap tensioners and locking components

3D Printing Recommendations

I printed the structural components using Bambu Lab PETG HF on a Bambu Lab 3D printer.

For the ground-contact sole, I used TPU 95A, a flexible, rubber-like filament that provides better grip and cushioning than rigid plastic.

Materials used:

• PETG HF – main structural components
• TPU 95A – flexible ground-contact sole
• Aluminum tubes – 20 mm and 32 mm diameter

Please pay special attention to print orientation, layer adhesion, wall thickness, and infill settings, especially for load-bearing components.

The materials and settings used in my prototype are not a guarantee of structural strength or safety. Each printed component should be carefully inspected and tested before use.

Hardware and Assembly

Please note that I have not included a detailed Bill of Materials (BOM) for the fasteners and other hardware.

During assembly, I selected most of the screws, nuts, and other small components by trial and error, using whatever I had available. Unfortunately, I can no longer recall all the exact sizes and lengths.

You will therefore need to select some of the hardware yourself based on the 3D models and your particular assembly.

Sorry for the inconvenience, but I hope the included STEP files will make this easier!

EDIT: I added iwalk2-screws.pdf with all hardware for your convenience!

Important Safety Disclaimer

This is an experimental DIY mobility aid, not a certified medical device.

Although the design has been successfully used in real life, its strength and safety have not been professionally tested or certified.

3D-printed parts can fail unexpectedly depending on the material, print settings, orientation, and loads applied.

Build and use at your own risk. Carefully inspect all parts before use, and consult a healthcare professional to determine whether a hands-free crutch is appropriate for your injury and stage of recovery.