A New Era in Prosthetics: The Dual Y Nexxus Harness

Pictured: Bahar Hashemian Esfahani (left) with Dr. Rachel Eike (right).

For Iowa State University researchers Dr. Rachel Eike and PhD candidate Bahar Hashemian Esfahani, the journey to redefining prosthetic harness design began with a simple classroom challenge. Now, thanks to their innovative Dual Y Nexxus harness and collaboration with CyBIZ Lab, they’re on the path to transforming an industry that has seen little change in decades.

It all started in one of Dr. Eike’s functional design courses, where students are tasked with solving real-world problems through research and innovation. The challenge? To redesign the outdated ‘Figure of 9’ harness used by individuals with upper limb body-powered prosthetics—an essential but uncomfortable device that had remained largely unchanged since the 1960s. Bahar’s design stood out, and what began as a class project in Fall 2021 has since grown into a patented innovation.

The Dual Y Nexxus harness replaces the traditional Figure of 9 with a more ergonomic design—featuring a Y-shaped fabric structure in the front and back with an anchoring point for a ball socket. By focusing on material improvements and stability, Bahar and Rachel have refined the design over multiple semesters, incorporating feedback from users and experts alike. Recognizing the potential impact of their product, they secured a $50,000 Innovation Accelerator Fund (IAF) grant to accelerate their journey to market.

Dual Y Nexxus prototype.

To bridge the gap between design and commercialization, Bahar and Rachel turned to CyBIZ Lab. The CyBIZ Lab student consulting team was instrumental in identifying distribution channels for the Dual Y Nexxus harness, preparing the duo for crucial industry conversations, and providing market research. One of their key recommendations—attending the American Academy of Orthotists and Prosthetists (AAOP) conference—proved beneficial. With targeted goals and conversation strategies developed with the help of the CyBIZ students, Rachel and Bahar connected with key distributors and gained insights that will shape their next steps.

Beyond conference prep, CyBIZ Lab compiled a database of potential distributors, complete with contact information—a resource Rachel describes as invaluable. “The students compiled all of these contacts for us in one nice little package. The research they did has been so helpful, and we refer back to it often,” she shared. “We are designers, and these students have a business focus, so they have experience gathering data in a way that we do not. It was great to tap into this resource.”

Now part of the ISU Startup Factory, Rachel and Bahar continue to push their innovation forward. They are actively working with Iowa-based soft goods manufacturers to test functional fabrics, ensuring the harness remains secure and comfortable during movement. But the pair are also expanding their vision beyond the Dual Y Nexxus. Their long-term goal? To launch WearLab Solutions, a consulting and research-based company that bridges the gap between academic research and functional products—offering protective, performance-enhancing, and comfort-focused solutions for real-world challenges. “We know how to conduct research, we know how to ask the right questions, and we have the prototyping and fabrication skills to build these products,” Rachel explained. Bahar’s background—owning a fashion company in Iran—has given her expertise in pattern making and garment construction that further strengthens their capabilities.

“This project has grown beyond what we initially imagined,” Rachel reflected. “Every semester, we learn more, ask better questions, and refine our product thanks to the insights and expertise of those we’ve worked with—including CyBIZ Lab. Their support has been invaluable.”

Together, they believe WearLab Solutions can be the space where innovation, research, and real-world functionality meet —one design challenge at a time.