Nevro EPS Lower Limb Harness

Nevro EPS Lower Limb Harness

Nevro, a medical company dedicated to freeing patients from chronic pain, partnered with Interwoven to design a soft goods wearable that secures an external power supply over a peripheral nerve stimulation implant in the lower limb. New technology allows nerve stimulation implants to be smaller than ever, and Nevro’s peripheral nerve stimulation technology uses an external power supply (EPS) device that sits outside the skin, powering the implant through near-contact charging rather than being permanently implanted in the body as part of the stimulation device. Successful charging requires the external power supply to sit tightly against the body within a small range of distance from the implant, and Interwoven’s challenge was to develop a wearable that would conform to the body comfortably, hold the power supply securely in place over the implant, and fit a wide range of users on both the calf and the thigh.

Interwoven executed a full design process—from research to high-resolution manufacturing prototypes—to develop a flexible, comfortable solution for both the upper and lower leg. This project extended Interwoven’s earlier collaboration with Nevro on a shoulder wearable for the same peripheral nerve stimulation device accessory collection.

What we did

Design Research
Competitive Analysis
Materials Research
Sourcing
Branding
Technical Design
Prototyping
Small Volume Production

Clients / Collaborators

Nevro

Product Description

The Nevro External Power Supply (EPS) Lower Limb Harness is an adjustable harness that holds an external power supply device in place over a peripheral nerve stimulation leg implant, which may be located in the calf or thigh. The wearable uses a combination of elastic, Velcro, and perforated Lycra to create a comfortable harness with durable stretch and breathability.

Features & Benefits

Interwoven developed a tapered structure with elastic strategically incorporated in a diamond configuration to both hold the EPS securely in place and allow for a comfortable, snug fit that would keep the EPS in place during low-impact activity. The main body elastic was selected to be durable and high recovery, ensuring that the wearable would retain elasticity over time. Perforated lycra lines the back of the wearable, adding breathability and comfort for prolonged wear. The lower limb wearable is low profile, allowing the wearable to wrap around the thigh once or around the calf multiple times without becoming bulky. This, along with the mesh liner, improves thermal comfort.

A secondary adjustment strap allows for a more precise and customizable fit, ideal when the user is changing positions. When moving from a seated to a standing position or vice versa, thethigh circumference changes. The secondary strap allows the user to tweak the fit of the wearable quickly and easily, without needing to fully doff and don again. A TPU frame holds the EPS securely in place within a lycra pocket on the wearable, and is backed by a stiffer nylon that prevents the EPS from falling out accidentally and further stabilizes it.

Design Process

Key success metrics for the project included easy implant alignment, secure positioning, and overall comfort. With the external power supply dimensions and weight predetermined, the challenge was balancing functionality, comfort, and aesthetics while maintaining consistency with the rest of the collection and addressing the diverse needs of Nevro’s patient population.

Development

Interwoven aimed to use a minimal number of materials to keep manufacturing costs down and to repurpose those materials elsewhere in the collection, enabling the client to source materials more efficiently.

Branding

Interwoven designed a custom pull tab and a soothing colorway to reﬂect the design and styling of the existing shoulder wearable. The pull tab introduces a pop of color and enhances the garment with a high-quality interaction, reinforcing the user’s perception of the product’s value. It was intentionally designed to create continuity and coherence across all elements of the collection.

WORK WITH US

What we did

Clients / Collaborators

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