PRODUCT TIERS
CAPRASTRIDE™ CONSUMER
Restore natural mobility. Gait-adaptive assist for daily life, rehabilitation, and fall prevention.
- Lightweight carbon-fiber frame (~3 kg total)
- 12V brushless passive-assist actuators, ~50 Nm
- 8+ hours daily battery life
- Fall-prevention via real-time balance monitoring
- Bluetooth app for gait analytics and physiotherapy
- Streamlined form factor for under-clothing wear
CAPRASTRIDE™ PROSUMER
Augment human work capacity. 30-40% fatigue reduction under sustained loads for industrial and first responder use.
- Carbon-fiber + 7075-T6 aluminum frame (~5 kg)
- 24V brushless + harmonic drive, ~100 Nm sustained
- 6-8 hours under continuous load carry
- Joint encoders + 3-axis IMU gait optimization
- CapraPack™ slide-lock for shared power bus
- Impact-resistant shell for harsh work environments
CAPRASTRIDE™ MILITARY
Maximum capability under fire. 50% fatigue reduction with full combat load, ballistic shin guards, and 72-hour field endurance.
- Mil-spec carbon-fiber + titanium joints (~6.5 kg)
- 24V brushless + harmonic drive, ~150 Nm peak
- UHMWPE ballistic shin and knee armor panels
- Full CapraCore™ integration via CapraLink™ MIL
- CapraHooves™ docking cleat for powered boots
- Hot-swap CapraVolt™ batteries, 4-6 hr combat
DRIVE SYSTEM
24V Brushless Motors
High-torque 24V brushless DC motors at hip and knee joints deliver up to 150 Nm through precision harmonic drive reducers. Silent, efficient, and maintenance-free.
Harmonic Drive Actuators
Strain-wave gearing provides zero-backlash torque multiplication in a compact, lightweight package. 160:1 reduction ratio delivers smooth, precise joint articulation.
Series Elastic Elements
Compliant series elastic actuators between motor and joint absorb impact loads, protect drive components, and enable natural-feeling gait dynamics during walking and running.
GAIT INTELLIGENCE
Joint Encoders
High-resolution magnetic encoders at every joint track angular position and velocity at 1 kHz. The control loop knows exactly where your legs are at all times.
3-Axis IMU Array
Inertial measurement units on each leg segment and the hip module provide full spatial awareness. Accelerometer, gyroscope, and magnetometer data fused at 200 Hz.
Predictive Gait Model
Machine learning gait model adapts to the wearer's stride pattern within 60 seconds. Predicts intent before muscle activation and pre-positions actuators for seamless assist.
Terrain Adaptation
Automatic gait profile switching for flat ground, stairs, slopes, and rough terrain. The system detects surface changes via foot pressure and IMU data and adjusts torque curves in real time.
MATERIALS PLATFORM
CARBON-FIBER CFRP
Unidirectional T700 prepreg primary members with 2x2 twill T300 at joint interfaces. Autoclave-cured 177°C / 90 psi for <1% void content. Provides maximum axial stiffness at minimum weight — the entire exoframe weighs under 2 kg bare.
7075-T6 ALUMINUM
Aircraft-grade aluminum at hip and knee pivot housings. 572 MPa ultimate tensile at 2.81 g/cm³. CNC-machined from billet for consistent grain structure. Type III hard-anodized (50 μm) for bearing surface wear resistance.
Ti-6Al-4V TITANIUM
Grade 5 titanium alloy at series elastic elements and critical fasteners. 900 MPa yield strength at half the weight of steel. Fatigue-rated for 10 million cycles at design load — the joints that flex every stride never fail.
SYSTEM STATUS
Fatigue index, joint torque, and gait phase reported to CapraHelm™ HUD in real time via CapraLink™.
STRUCTURAL DESIGN
Carbon-Fiber Frame
Unidirectional carbon-fiber composite frame provides maximum stiffness at minimum weight. Anodized 7075 aluminum alloy at high-stress joint interfaces for fatigue resistance.
Adjustable Geometry
Telescoping thigh and shin segments adjust to individual leg length. Tool-free sizing for rapid fitting across body types from 5th to 95th percentile.
Ballistic Shin Guards
Optional UHMWPE ballistic shin and knee armor panels mount to the exoframe rails. Military tier includes full lower-leg coverage rated to fragmentation and handgun threats.
POWER INTEGRATION
CapraPack™ Interface
Slide-lock connector at the hip belt docks directly to the CapraPack™ backpack module. Shared power bus feeds CapraStride™ from the central CapraVolt™ battery array.
Hot-Swap Power
CapraVolt™ battery modules swap without powering down the exoskeleton. Supercapacitor bridge maintains actuator power during the 3-second changeover window.
CapraHooves™ Docking
Quick-release mechanical cleat at the ankle interfaces with CapraHooves™ powered boots. Combined system delivers continuous power from hip to toe with coordinated gait control.
Intelligent Power Routing
CapraCore™ manages power distribution across all connected modules. Low-battery mode prioritizes knee actuators over hip assist to maintain mobility as charge depletes.
FAIL-SAFE DESIGN
Passive Backdrivability
If power fails, all joints remain freely backdrivable. The exoskeleton becomes a lightweight frame you walk through, not a cage that traps you.
Emergency Quick-Release
Two-point quick-release buckles at hip and ankle allow complete removal in under 5 seconds. Operable with gloved hands in any body position.
Overload Protection
Torque limiters and current sensors prevent actuator overload. If a joint encounters unexpected resistance, the motor reduces power rather than forcing through.
Degraded Mode Operation
Single actuator failure does not disable the system. Remaining motors compensate and the gait model adapts to maintain balanced assist on the functioning joints.
DEPLOYMENT SCENARIOS
LOAD CARRYING
- Sustains 80+ lb ruck loads over 20 km+ dismounted patrols
- Hip and knee actuators absorb 30-50% of load-bearing fatigue
- Gait model auto-adjusts torque curves for uphill, downhill, and flat terrain
- Reduces cumulative musculoskeletal injury risk across multi-day operations
CASUALTY EVACUATION
- Fireman carry and drag assist modes provide up to 40% force amplification
- Dual-operator litter carry mode synchronizes gait between two exo-equipped operators
- Sprint-burst mode overclocks actuators for 30-second high-output evacuation runs
- CapraCore AI auto-detects carry posture and switches to appropriate assist profile
OBSTACLE NEGOTIATION
- Stair ascent mode pre-loads knee extensors for each step, reducing quad fatigue 45%
- Rubble traverse mode increases ankle stabilization torque and shortens stride length
- Ladder climb mode locks hip angle and provides vertical push assist
- IMU-based terrain classification switches modes automatically within 2 gait cycles
EXTENDED PATROL
- 12+ hour continuous operation on dual CapraVolt 150 Wh battery modules
- Metabolic cost reduction of 15-25% at walking pace extends effective range by 30%
- Passive mode provides joint bracing without power draw for stealth phases
- Fatigue index tracking via IMU gait degradation warns operator before performance drop
BIOMECHANICS
STANCE PHASE ASSIST
During heel strike through mid-stance (0-40% gait cycle), the knee actuator provides eccentric braking torque to absorb impact loads. At terminal stance (40-60%), concentric extension assist drives push-off. Peak torque output of 150 Nm matches the biological knee moment during loaded walking.
SWING PHASE ASSIST
During swing phase (60-100% gait cycle), the hip flexor actuator lifts the loaded leg forward. The system reduces the metabolic cost of leg swing by 30-40%, which dominates fatigue during heavy rucking. Harmonic drive gearbox provides zero-backlash torque transfer for precise trajectory control.
METABOLIC COST REDUCTION
Measured via indirect calorimetry (VO2 consumption) during treadmill and overground trials. At 4.5 km/h with 35 kg load, the CapraStride reduces oxygen consumption by 15-25% compared to unassisted walking. This translates to approximately 30% increase in effective patrol range before reaching the same fatigue threshold.
LOAD DISTRIBUTION
The carbon-fiber exoskeleton frame transfers 40-60% of backpack load directly to the ground through the structural members, bypassing the operator’s spine and knees. Load sensors in the hip belt and thigh cuffs continuously measure distribution and alert when asymmetric loading exceeds 15% side-to-side differential.
JOINT TORQUE CURVES
The CapraCore AI maintains a real-time torque profile for each joint based on terrain, speed, load, and operator fatigue. Torque curves are not fixed lookup tables—the system uses a reinforcement-learned gait model that adapts within 3-5 strides of a terrain or load change. Operators report the system “disappears” after 10-15 minutes of calibration walking.
GROUND CLEARANCE
Swing phase hip flexion assist increases minimum toe clearance by 15 mm on average, significantly reducing trip/stumble incidents during fatigued walking. The system detects gait degradation patterns (shortened stride, reduced clearance) and proactively increases assist before the operator trips.
PERFORMANCE MATRIX
| SPECIFICATION | CONSUMER | PROSUMER | MILITARY |
|---|---|---|---|
| Knee Torque | ~50 Nm | ~100 Nm | ~150 Nm |
| Hip Torque | ~30 Nm | ~60 Nm | ~100 Nm |
| System Weight | ~3 kg | ~5 kg | ~6.5 kg |
| Battery Life | 8+ hrs | 6-8 hrs | 4-6 hrs |
| Load Capacity | Daily assist | 30-40 kg | 50+ kg |
| Ballistic Armor | — | — | ✓ |
| CapraHooves™ Dock | — | ✓ | ✓ |
| CapraCore™ Link | BLE App | CAN-FD | CAN-FD MIL |
| Gait Learning | ✓ | ✓ | ✓ |
MATERIALS SCIENCE
| CARBON-FIBER FRAME | Unidirectional T700 prepreg layup for primary structural members (thigh, shank tubes) providing maximum axial stiffness-to-weight. Woven 2x2 twill T300 at joint interfaces and attachment points where multi-directional loads dominate. Autoclave-cured at 177°C / 90 psi for void content below 1%. |
| 7075-T6 ALUMINUM JOINTS | Aircraft-grade aluminum alloy for hip and knee pivot housings. 7075-T6 provides 572 MPa ultimate tensile strength at 2.81 g/cm³ density. CNC-machined from billet (not cast) for consistent grain structure. Hard-anodized Type III coating (50 μm) for wear resistance at bearing surfaces. |
| HARMONIC DRIVE GEARBOX | Strain-wave gear reducer at each powered joint. 100:1 reduction ratio converts high-speed brushless motor output to high-torque, low-speed joint actuation. Zero backlash design eliminates mechanical slop for precise gait control. Rated for 50,000+ hour MTBF at nominal load. |
| BRUSHLESS MOTORS | 24V outrunner BLDC motors with rare-earth NdFeB magnets. 200W continuous, 400W peak per joint. Hall-effect commutation with 14-bit absolute encoders for position feedback at 1 kHz update rate. Sealed IP54 housings with integrated thermal monitoring. |
| CAN-FD BUS | Controller Area Network with Flexible Data-rate (CAN-FD) backbone connecting all joint encoders, IMUs, and the CapraCore compute module. 5 Mbit/s data rate supports 1 kHz sensor fusion loop. Twisted-pair shielded wiring routed through the carbon-fiber frame channels. Bus arbitration ensures motor commands have priority over telemetry. |
| UHMWPE SHIN GUARDS | Optional ballistic shin panels molded from ultra-high-molecular-weight polyethylene (Dyneema HB212). Provides NIJ Level II ballistic fragmentation protection at 0.4 kg per panel. Snap-in attachment to the exoskeleton shank tubes; removable in under 10 seconds for weight reduction when ballistic threat is low. |
SYSTEM INTEGRATION
CAPRAHOOVES™ DOCKING
The CapraStride ankle interface terminates in a slide-lock cleat that docks directly into the CapraHooves boot shaft. A quarter-turn locks the mechanical, power, and data connections. The boot provides ground-truth force data (GRF sensors, foot IMU) that feeds back into the exoskeleton gait model. When undocked, CapraStride operates with reduced gait fidelity using its own shank-mounted IMUs.
CAPRAPACK™ BELT CONNECTION
The hip frame connects to the CapraPack dorsal frame via a slide-lock belt interface. This provides structural load transfer (backpack weight routes through the exo frame to ground), power delivery (CapraVolt battery modules supply 24V to all joint actuators), and CAN-FD data bus access to the CapraCore compute module. Hot-swap capable: the belt can be disconnected without powering down the exoskeleton.
CAPRALINK™ PROTOCOL
Each CapraLink connector carries power (24V / 5A max), CAN-FD data (5 Mbit/s), and a secondary I2C bus for low-priority sensor polling. MIL-spec twist-lock geometry with IP67 environmental sealing. Connector pins are gold-plated beryllium copper for corrosion resistance and low contact resistance across 10,000+ mate cycles.
GRACEFUL DEGRADATION
If the CapraLink connection to CapraCore is lost, the exoskeleton enters autonomous mode: a local STM32 microcontroller runs a simplified gait model using only the leg-mounted IMUs and encoders. Assist torque drops to 60% of nominal but the system remains safe and functional. If battery is depleted, all joints free-wheel with minimal mechanical resistance—the exo becomes a passive frame, not a locked cage.
ACCESSORIES & ADD-ONS
UHMWPE Ballistic Shin Guard Kit
Snap-in Dyneema HB212 shin panels providing NIJ Level II fragmentation protection. 0.4 kg per panel. Removable in under 10 seconds for weight reduction when ballistic threat is low. Covers tibial shaft from knee to ankle.
Arctic Operation Thermal Boot
Insulated over-boot shell rated to -40°C. Integrates with the CapraStride ankle cleat without modification. Battery-heated insole draws power from the exoskeleton’s CapraVolt supply. Compatible with CapraHooves docking interface.
Quick-Release Ankle Cuff
Emergency disconnect cuff that allows the operator to separate from the exoskeleton in under 3 seconds. Pull-tab shear-pin mechanism releases the thigh and shank attachments simultaneously. Required for maritime and airborne operations where entanglement is a lethal risk.
Cargo Frame Attachment
Bolt-on cargo rail system that attaches to the exoskeleton’s thigh and shank tubes. Provides external mounting points for ammunition cans, water containers, breaching tools, and medical kits. Transfers cargo weight through the exo frame to ground, bypassing the operator’s body entirely.
BILL OF MATERIALS
| Component | Specification | Category |
|---|---|---|
| Exoframe (per leg) | UD carbon-fiber composite + 7075-T6 aluminum joint housings | STRUCTURE |
| Knee Actuator (x2) | 24V BLDC + harmonic drive, 150 Nm peak, 160:1 ratio | DRIVE |
| Hip Actuator (x2) | 24V BLDC + harmonic drive, 100 Nm peak, 120:1 ratio | DRIVE |
| Series Elastic Element (x4) | Titanium torsion spring, 2.5 Nm/deg stiffness | COMPLIANCE |
| Joint Encoders (x4) | 14-bit magnetic absolute encoder, 1 kHz sampling | SENSORS |
| IMU Array (x3) | 6-DOF MEMS IMU per segment (thigh, shin, hip), 200 Hz | SENSORS |
| Motor Controller (x4) | FOC controller, CAN-FD bus, 48V/30A rated | ELECTRONICS |
| Wiring Harness | MIL-SPEC shielded twisted pair, IP67 connectors | ELECTRICAL |
| Shin Armor (optional) | UHMWPE multi-layer laminate, NIJ IIIA rated | PROTECTION |
| Hip Belt Assembly | CORDURA 1000D + aluminum slide-lock CapraPack™ interface | INTERFACE |
| Ankle Cleat | Quick-release mechanical dock for CapraHooves™ | INTERFACE |
| Comfort Liner | TENCEL moisture-wicking pads, replaceable | COMFORT |
RISK ANALYSIS
Actuator Reliability Under Combat Load
Harmonic drives degrade under sustained high-torque shock loading. Mitigation: series elastic elements absorb transients; accelerated life testing at 2x rated load; field-swappable actuator modules.
Battery Duration vs. Weight
Military tier at 150 Nm sustained draw depletes batteries in 4-6 hours. Mitigation: CapraPack™ shared power bus; intelligent power routing; hot-swap CapraVolt™ modules; low-power passive-assist fallback mode.
Gait Model Adaptation Latency
Untrained users may experience 30-60 seconds of suboptimal assist while the ML gait model calibrates. Mitigation: pre-loaded gait profiles by body type; manual override for immediate torque curves; progressive ramp-up on first wear.
Joint Alignment Under Asymmetric Load
Off-axis loads during lateral movement can stress joint bearings. Mitigation: spherical bearing inserts at knee and hip; load-path monitoring via strain gauges; automatic torque limiting on misalignment detection.
EMI Interference with CapraCore™
Motor PWM switching may create electromagnetic noise on CapraLink™ data bus. Mitigation: shielded twisted-pair wiring; CAN-FD differential signaling; ferrite chokes at connector interfaces.
Environmental Ingress
Mud, water, and debris entering actuator housings during field operations. Mitigation: IP67-rated actuator enclosures; labyrinth seals at rotating joints; field-serviceable drain ports and replaceable filters.
PROTOTYPE ROADMAP
ACTUATOR VALIDATION
Single-joint test rig: harmonic drive endurance testing at 150 Nm peak, series elastic element tuning, motor controller FOC optimization. 10,000-cycle fatigue qualification.
GAIT CONTROL PROTOTYPE
Full bilateral exoskeleton on treadmill rig. ML gait model training across 50 body types. Terrain adaptation testing: stairs, slopes, uneven ground. CapraPack™ power integration.
FIELD TRIALS
Outdoor load-carry trials with military advisors. 72-hour sustained-wear evaluation. CapraHooves™ integration testing. Ballistic shin guard qualification. Environmental stress screening.
PRODUCTION HARDENING
Manufacturing process validation. MIL-STD-810H environmental qualification. Supply chain for harmonic drives and carbon-fiber exoframes at scale. Consumer and prosumer tier certification.
AUGMENTED MOVEMENT
The human leg generates approximately 80 Nm of torque at the knee during walking. Under a 50 kg combat load, that number doubles and fatigue accumulates exponentially. CapraStride™ doesn't replace your legs. It matches them. Every stride, every step, every hill. The exoskeleton learns your gait, predicts your next move, and delivers precisely the torque you need before you feel the strain. The operator who walks 20 km with 50 kg arrives as fresh as the one who walked 5 km with nothing.
FREQUENTLY ASKED QUESTIONS
The Military tier delivers 30-50% fatigue reduction under full combat load (50+ kg). The system measures metabolic cost reduction via gait analysis and adjusts torque delivery in real time. Prosumer and Consumer tiers provide proportional assistance scaled to their actuator capacity.
All joints remain freely backdrivable. The exoskeleton becomes a lightweight passive frame with zero resistance to natural movement. You can walk, run, and maneuver normally. The system adds approximately 3-6.5 kg of carried weight depending on tier, but never locks or restricts your joints.
Yes. Through the CapraCore™ computing hub and CapraLink™ connectors, the CapraStride™ reports gait data, fatigue index, joint torque, load estimation, and battery status directly to the CapraHelm™ HUD. The operator sees exoskeleton telemetry alongside all other system data.
A quick-release mechanical docking cleat at the ankle interfaces with the CapraHooves™ powered boots. The combined system provides continuous powered assist from hip through knee to foot with coordinated gait control managed by CapraCore™.
The Military tier includes mounting rails for UHMWPE ballistic shin guards and knee armor panels rated to fragmentation and handgun threats. These panels are optional and removable. Consumer and Prosumer tiers omit ballistic protection for weight reduction.
Full donning takes approximately 90 seconds with practice. The hip belt secures first, then each leg segment locks via quick-adjust cam buckles. Telescoping segments self-adjust to leg length after initial sizing. Emergency removal via quick-release takes under 5 seconds.
The onboard ML model analyzes joint angles, ground reaction timing, and IMU data to build a personalized gait profile. Initial calibration takes 30-60 seconds of walking. The model continuously refines as you move, automatically switching profiles for stairs, slopes, and rough terrain.
The Military tier is engineered for operators carrying 50+ kg of combat load. The system assists proportionally to load, with peak torque of 150 Nm at the knee joint. The Prosumer tier handles sustained loads of 30-40 kg typical of construction and logistics work.
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