Introducing the Icarus Hercules KAFO

At Icarus Medical, we’re proud to offer the patented Hercules KAFO – an advanced knee-ankle-foot orthosis that offers a range of unique features and benefits for patients who need extra support and assistance with their mobility. One of the most notable features of the Hercules KAFO is its bicentric hinge, which generates torque and a “swing-assist” using an elastomeric tensioning system that the user can fully adjust. This means that patients can customize the level of support they need based on their specific needs and preferences.

What Is The Hercules KAFO?

The Hercules KAFO, in addition to stabilizing and supporting the knee and ankle, is designed to unload the knee for a range of tension settings and provide stance control at maximum tension levels. This makes it a versatile option for patients who need extra support for a range of activities, from simple sitting and standing to more strenuous physical activities like playing sports.

One of the most exciting aspects of the Hercules KAFO is its 3D-printed, lightweight design. Patients can even opt to have the brace customized from a 3D scan taken from an iPhone (though traditional casting is also an option). This ensures that the brace is as comfortable and form-fitting as possible while providing the necessary level of support. To learn more about the Hercules KAFO and its innovative design, we sat down with Ben Scire, the lead engineer at Icarus Medical. Here’s what he had to say:

“One of the most exciting features of the Hercules KAFO is its swing assist technology, which allows patients to smoothly transition from knee motion to swing assist with a simple turn of the motion. Once in swing assist mode, patients can enjoy greater support as they move into flexion, making it easier to perform a range of activities with greater ease and comfort. And if they need even more support, they can increase the tension to reach full knee immobilization, providing maximum stability and protection.”

What Is The Difference Between the Hercules KAFO and Others on the Market?

The Hercules KAFO is groundbreaking for a number of reasons. One of the most notable features of the Hercules KAFO is that it incorporates all the features found in the Icarus Ascender knee brace into a KAFO. This includes an adjustable swing assist mechanism with dynamic capabilities to adjust the unloading force within the device. Due to the Hercules’ unique tension dialing system, users can adjust this feature on the go and based on their needed support level. On top of that, when coupled with our customizable design, we are able to create a KAFO that fits the patient’s leg to perfection while also providing the added benefit of unloading the patellofemoral compartment.

What Features Set the Hercules KAFO Apart?

The standout feature of the Hercules KAFO is its impressive lightweight design, weighing in at just 26 ounces, making it the lightest KAFO available. Moreover, our innovative tension lock system sets it apart from other knee braces on the market, delivering superior unloading strength. With the tension dial, wearers can adjust the level of tension to their liking, with the highest setting providing complete knee immobilization.

In contrast to traditional KAFOs, which only offer a drop lock mechanism to lock or free the knee joint, the Hercules KAFO provides an unprecedented range of adjustability, allowing users to set tension levels anywhere between full power and zero. This means that the wearer can dial in a specific level of tension that suits their needs, ranging from 50% to 80% of mobilization, something never before available in the KAFO market.

How Does the Customization Process Work?

At Icarus Medical, we use high-tech 3D printing technology to create a custom brace perfectly tailored to the patient’s leg. This process involves taking a 3D scan of the patient’s leg using our specialized iPhone app. This allows us to obtain a precise digital model of the leg, which we use to design a brace that is tailored to the patient’s unique contours, so the brace fits like a glove. Once the design is complete, we use cutting-edge 3D printing technology to bring it to life. The resulting device is visually appealing and lightweight and remarkably strong, delivering a comfortable and snug fit that feels as if it were made specifically for the wearer’s leg.

Benefits of The Ability of the Brace to Detach

One of our unique features, not yet found in the market, is the ability to detach the KO and AFO components from the KAFO to create individual braces. With a simple separation, wearers have the option to wear just an AFO or KO, depending on their condition and level of instability on a given day. For example, a patient experiencing varying instability might prefer to wear an AFO only on certain days instead of the full KAFO. Similarly, those who only require a knee brace around the house can detach the AFO and wear the KO on its own. When the need arises, wearers can easily reattach the components to form the full KAFO for maximum support.

Who Can Benefit Most from the Hercules KAFO?

The Hercules KAFO is an excellent solution for patients suffering from neuromuscular disorders such as Ms, CP, CMT, post-stroke patients, polio patients, and others who require both ankle and quadricep support. As someone who personally experiences Charcot-Marie-Tooth Disorder (CMT), I developed the first prototype of this device to address my drop foot and quadriceps weakness. The KAFO’s AFO portion provided outstanding support for my ankle, while the dynamic swing assist control offered by the Hercules KAFO gave me much-needed quadricep support.

If your patients have any of these conditions, the Hercules KAFO would be an excellent option for them. It is significantly less bulky than other KAFOs on the market and offers users the ability to adjust the level of support they require as needed. The best part is that they can adjust the support on the go, depending on their activities or the discomfort they may be experiencing on a given day. Keep the Hercules KAFO in mind; it is a groundbreaking technology in the world of KAFOs, and Icarus is proud to offer this innovative solution to our patients.

Choosing a KAFO Knee Brace

When it comes to KAFO braces, the Hercules KAFO is like no other. Unlike other options on the market, this advanced device offers a range of features that make it a top choice for patients who require additional support and assistance with their mobility.

Here are just a few of the features that set the Hercules apart:

Adjustable & High-Torque Swing-Assist

One of the most innovative features of the Hercules is its swing-assist mechanism, which can be adjusted to provide different levels of support based on a patient’s specific needs. This feature can also be locked out if necessary, providing even more control.

Multi-compartmental Unloading

For patients who need extra support for their knees, the Hercules offers a unique multi-compartment unloading system that helps to distribute weight evenly and reduce pressure on the joint.

3D Printed and Form Fitting Design

Using cutting-edge 3D scanning and printing technology, the Hercules is designed to be an extremely lightweight and form-fitting brace. This makes it more comfortable to wear for extended periods and ensures that it provides the right amount of support exactly where it’s needed.

Detachable AFO & KO Components

 Finally, the Hercules offers a detachable feature that allows patients to wear the AFO and KO components of the brace individually if desired. This provides even more flexibility and control over how the brace is worn, making it a versatile option for a range of different needs.


Overall, if you or someone you know is in need of a KAFO brace that offers exceptional support, comfort, and flexibility, the Hercules KAFO is definitely worth considering. Its innovative features and customizable design could be just the solution you’ve been looking for.

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Most braces are covered by insurance and the average cost is under $200!

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