Systematic process for design and manufacturing of ergonomic handles for para-table tennis: a case study

Abstract

Wheelchair table tennis serves as an affordable and accessible means of enhancing the physical and psychological well-being of individuals with tetraplegia; however, limited hand mobility and grip strength continue to constrain performance. To address these issues, this study presents a systematic, end-to-end workflow for designing and manufacturing customized, competition-legal table tennis handles tailored to tetraplegic athletes, evaluated through a single-athlete feasibility case study rather than a clinical or sports-performance validation. The process integrates hand geometry capture, computer-aided design (CAD) refinement through iterative additive prototyping, and final fabrication using optimized materials and surface finishing. To evaluate the effectiveness of the proposed approach, a case study was conducted comparing an athlete’s performance using the old and new handles in terms of accuracy, control, and overall playing performance. In this single-athlete case study, successful shots showed roughly $$2.4\times$$ the odds of success with the new handle across drills. As a proof-of-concept evaluation, these findings are preliminary and indicate an association observed in one athlete, not a demonstrated causal effect, and are not intended to generalise to tetraplegic players more broadly. The customized handle was also reported by the athlete to be more comfortable and easier to use.