Development notes

A documented timeline of the LETO 1 mechanical, electronics, and prototyping work recorded from October 2025 through June 2026.

Archive note

Source images from internal development updates are paired with the milestone they document most directly. Entries remain text-only where the available archive does not clearly show that specific test or decision.

9 documented milestones12 source images

Hand CAD foundations

The development archive began with reference research and early Fusion 360 work. The hand skeleton, palm geometry, and finger structure were refined before moving toward a printable first-generation design.

Figure 01Open full size ↗
Fusion 360 workspace showing early hand, wrist, and skeletal reference geometry
Early Fusion 360 reference work comparing hand and wrist surface geometry.
Figure 02Open full size ↗
Front view of an early hand shell and palm model in Fusion 360
Front view of the first hand shell and palm geometry used to establish overall proportions.

First rapid prototype

The first-generation hand moved from CAD into rapid prototyping. Printing the model created a physical baseline for checking proportions, clearances, joint movement, and the practical assembly of the mechanism.

Figure 01Open full size ↗
3D-printer control screen showing the first hand skeleton prototype being printed
The first skeleton prototype in progress on the printer, creating a physical baseline for assembly checks.

Joint testing exposed design limits

Real-world flexion tests revealed knuckle hyperextension and excess fingertip extension. The discussion focused on adding a mechanical stop and revising tendon leverage so the fingers could close reliably without binding.

EMG signal and power planning

Initial electronics work documented an EMG signal-amplifier path and an updated ESP32 power supply. These schematics established the sensing and control foundation for later motor-driver and PCB integration.

Figure 01Open full size ↗
EMG analogue front-end schematic with instrumentation and operational amplifiers
EMG analogue front end: instrumentation amplification, gain, rectification, smoothing, and buffered output.
Figure 02Open full size ↗
Power regulation and reference-voltage schematic for the sensing electronics
Power path for the sensing electronics, including 5 V and 3.3 V regulation plus the buffered VREF rail.
Figure 03Open full size ↗
Block diagram showing passive filtering, instrumentation amplification, ADC conversion, and ESP32 control
Early signal-chain planning from passive filtering and instrumentation amplification through ADC conversion and ESP32 control.

Mechanical architecture redesign

The hand was reworked around a lighter linkage structure with routed tendons, revised finger geometry, and a more developed wrist interface. Successive renders show the mechanism becoming more compact and serviceable.

Figure 01Open full size ↗
Dark CAD render of the redesigned linkage hand with visible tendon paths
Reworked linkage architecture with routed tendon paths, revised finger segments, and a compact wrist interface.

Motor and gearbox packaging

Motor dimensions and torque requirements were reviewed against the available wrist volume. The packaging plan returned to planetary gearboxes for higher torque and reliability, accepting a tighter battery-space constraint.

Figure 01Open full size ↗
Sectioned Fusion 360 model showing motors, gears, tendon spool, wrist, and finger linkage
Sectioned CAD view used to evaluate motor, gearbox, spool, and tendon packaging through the wrist and finger.
Figure 02Open full size ↗
Physical five-motor actuation pack with wiring and white tendon spools
Physical five-motor actuation pack with wiring, printed carrier, and tendon spools.

Tendon-control module iteration

Physical testing led to a redesigned Tendon Control Module with PTFE inserts and improved cable retention. The archive then shows the mechanism integrated into a complete hand prototype with routed tendons and electronics wiring.

Figure 01Open full size ↗
Assembled tendon-driven hand prototype with motor pack, springs, and articulated printed fingers
Integrated hand prototype showing the motor pack, tendon routing, return springs, and articulated printed fingers.

Integrated electronics architecture

The EMG front end, power management, ESP32, and five motor-driver channels were consolidated into a circular board concept. The schematic and layout progressed toward a finalized fabrication-ready design.

Figure 01Open full size ↗
Multi-channel EMG acquisition schematic centered on an ADS1298 analogue front end
Expanded multi-channel EMG acquisition schematic centered on the ADS1298 analogue front end.

Board ordering and review

The completed board design was prepared for fabrication, followed by a manual PCB review report. This marked the transition from circuit planning into hardware production and final pre-fabrication checks.

Figure 01Open full size ↗
Top and bottom rendered views of the circular integrated electronics board
Top and bottom views of the circular integrated control-board layout prepared for fabrication.

LETO 1 is presented as an engineering concept and is not a certified medical device or commercially available prosthesis.