GEN-4 | Advanced Prototype

In July, we completed the GEN-4 prototype and implemented several major architectural changes that move Genesis closer to deployment readiness.

Transition to Belt Drive

GEN-4 marks our first shift from a gear-driven transmission (used in GEN-3) to a belt-driven system. This change reduces mechanical complexity while improving smoothness and acoustic performance. The belt drive also lowers part count and removes several wear-prone interfaces, increasing overall reliability.

Importantly, the modest weight increase from other upgrades was largely offset by eliminating the gear drive assembly. The result is a cleaner mechanical architecture with improved serviceability and long-term durability.

Increased Power and Responsiveness

We integrated an updated brushless motor, doubling output power relative to GEN-3. This significantly increases available unit torque and improves dynamic responsiveness under load. The higher power ceiling allows more precise control authority across gait phases and improves performance during high-demand transitions such as push-off and incline walking.

Integrated Joint Lockout System

GEN-4 introduces a mechanical joint lockout feature — a capability not commonly integrated into advanced powered prosthetics.

Users can mechanically lock the ankle in any chosen position through a simple physical engagement. This provides:

• Predictable behavior in critical environments

• Mechanical robustness independent of software state

• An additional layer of physical safety for tasks such as driving

A quick rotational engagement ensures immediate lockout, creating a redundant safety pathway layered on top of software-based control systems. This expands Genesis from being purely adaptive to being selectively deterministic when required.

Live User Testing

We are currently conducting live user testing with GEN-4. These sessions are directly informing deployment-focused design decisions for the Genesis Ankle, including ergonomics, reliability under daily use, and control tuning.

Modular Chassis Development

We also began incorporating modular chassis concepts that support interchangeable adapter systems. This allows broader compatibility across a range of amputees and limb configurations, supporting a scalable deployment strategy rather than a single fixed geometry.

GEN-4 represents a transition from iterative performance improvement to structural refinement and real-world validation. The lessons learned here are shaping the architecture of the production-ready Genesis Ankle.