Hybridleg – how technology turns dreams into reality
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The world of new technologies is a world of new possibilities. Unlimited and real. Thanks to the cooperation of specialists from various fields, innovative solutions are created that significantly improve the quality of life of the entire society. In this case, collaboration between CONTUR 2000 and Mazak realised a lower leg prosthesis for athlete Adrian Bąk.
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The rigid boundaries between seemingly separate industries have long ceased to exist. Nowadays, the strength is in an interdisciplinary approach, drawing on the experience and good practices of scientists, entrepreneurs and technologists. An example of such effective cooperation is the project of a hybrid lower leg prosthesis – HybridLeg.
Project genesis began with a man who set himself the goal of participating in the International Olympiad for the Disabled Cybathlon 2020. For the dream to come true, Mr. Adrian Bąk needed a lower leg prosthesis that would enable him to move efficiently.
The challenge was taken up by CONTUR 2000, a company dealing in machining metal parts as well as designing and implementing complete production lines. For the implementation of the project, a dedicated production line was created entirely based on Yamazaki Mazak machines.
Work on the HybridLeg project started in 2010 in a specially established research and development department of CONTUR 2000.

innovation in design
HybridLeg is more than a prosthesis. The design of the HybridLeg lower leg prosthesis itself is an innovation on an international scale. From the user’s perspective, it is primarily a reliable and comfortable solution that gives many more possibilities compared to traditional models. It is worth mentioning here at least three functionalities that put HybridLeg at the forefront of the most innovative technological solutions.
MODES OF OPERATION
HybridLeg enables the operation of the prosthesis in two modes: passive and active. Movement in passive mode is forced by the user, its triggering does not use energy from the battery, while in active mode, the movement comes from an external energy source (battery) and the engine. All thanks to the innovative transmission-clutch system. Thanks to this, the prosthesis itself switches to the energy-saving mode when it is stationary, allowing for extended working time and adjusts the drive mechanism depending on the ground on which the user is moving.
freedom of movement
Walking on a flat surface, going up or down stairs, walking over uneven surfaces, exercising. HybridLeg gives the user a feeling of greater fitness, allows for a wider range of movements.
LIGHT CONSTRUCTION
Two modes of operation significantly reduce the energy consumption of the prosthesis, which in turn affects the possibility of using a smaller energy source. A physically smaller energy source means lighter power components.

From design to product
Like all innovative solutions, HybridLeg was built on the basis of ideas. The team started conceptual work in 2010. Using 20 years of experience of CONTUR 2000 specialists, the project was intensively improved to meet the highest expectations.
Ultimately, a patent was created in the form of a specific clutch that was used in the HybridLeg design. The prosthesis was equipped with an innovative gear-clutch system, which enables the engaging and disengaging of the drive mechanism depending on the type of ground on which the user is moving on.
The next step was to create a dedicated production line that would precisely make the concept come true and the choice to use advanced Mazak solutions was made.
HybridLeg prosthesis components have been prepared and manufactured on the VTC-560/25 and QUICK TURN NEXUS 250-II MS machining centers. In such projects, what counts is versatility, flexibility, and the ability to accurately adjust the machine’s operation to specific tasks. The production of a prosthesis for human use must meet the highest requirements in terms of quality and fit.
HYBRIDLEG in practice
Mr. Adrian Bąk has been using the HybridLeg prosthesis for many months. It was his opinion that had a decisive influence on the success of the entire project. Looking through the prism of personal satisfaction and opportunities that have opened up for Mr. Bąk, we can talk about the spectacular success of the project.

