ExoLab.LLC — Engineering the Future of Human Mobility

Who is ExoLab

A DSP Engineer Who Needs an Exoskeleton

Greg Klassen spent three decades in digital signal processing — designing real-time filter architectures, tuning PID loops, and building embedded control systems from the ground up. He then spent years as a CEO, before a diagnosis of Spinocerebellar Ataxia Type 3 (SCA3) changed the plan.

SCA3 is a progressive neurological condition that attacks coordination, balance, and gait. Commercial exoskeletons exist — but none are designed for cerebellar ataxia, where the challenge is balance, not paralysis.

So Greg is building his own. Working from a six-acre property in Leesburg, Virginia, ExoLab is a one-man R&D operation applying 30 years of signal processing expertise to the hardest problem Greg has ever faced: getting himself back on his feet.

The lab pursues three goals simultaneously: personal mobility research, rigorous open documentation of the build process, and informed engagement with the commercial and investment exoskeleton landscape.

Current status: Phase 1 hardware on order. CubeMars AK80-9 actuators inbound. Software stack under development.

// DSP → Exo Control Mapping

PID Loop Tuning

Real-Time Filtering

State Machine Design

Embedded C / STM32

System Identification

Sensor Fusion / IMU

CAN Bus Protocol

Impedance Control

Build Documentation

The ExoLab Build Plan

A five-phase roadmap from benchtop motor control to a wearable bilateral exoskeleton assist system. Built on 30 years of DSP experience. Click any phase for details.

PHASE 01

Benchtop Motor Control

~$800

PHASE 02

Gait Sensor Platform

~$225

PHASE 03

Simulated Knee Joint

~$220

PHASE 04

Wearable Single-Joint

~$2,900

PHASE 05

Bilateral Hip + Knee

~$15,000+

PHASE 01 — Benchtop Motor Control

One motor. One controller. Your own PID loop. The CubeMars AK80-9 delivers 9Nm rated / 22Nm peak torque through an integrated brushless motor, planetary gearbox, encoder, and CAN driver — all in a single package. The MIT Mini Cheetah protocol runs over CAN bus. Objective: command torque, read position, tune a real impedance controller.

Component	Part	Cost	Notes
Actuator	CubeMars AK80-9 V3.0	~$500	48V, MIT CAN protocol, integrated encoder
CAN Interface	Waveshare USB-CAN-A	~$22	socketCAN on Linux, plug-and-play
Power Supply	MEAN WELL 48V 10A	~$90	Bench PSU — current-limited for safety
E-Stop	22mm latching mushroom switch	~$12	Non-negotiable. Within arm's reach always.
Frame	2020 Aluminum Extrusion	~$50	Rigid mount — 9Nm will move a light table
Controller	Raspberry Pi 5 or STM32G4	~$60	Python CAN stack or embedded C

PHASE 02 — Gait Sensor Platform

Pure sensing. No actuation. Strap IMUs and force-sensitive resistors to both legs and walk — on carpet, on gravel, on the six-acre property. Capture what SCA3 gait actually looks like at 500Hz. This data becomes the training signal for every control algorithm written in Phases 3–5.

Component	Part	Cost	Notes
IMU (×3)	ICM-42688-P breakout board	~$30 ea	32kHz sampling, significant upgrade from MPU-6050
Force Sensors	Interlink 402 FSR (×8)	~$6 ea	Heel, 1st/5th met head, big toe per foot
ADC	ADS1115 16-bit, I2C	~$13	4-channel analog read for FSRs
MCU	Teensy 4.1 (600MHz ARM M7)	~$30	Real-time capable; DSP-friendly architecture
Storage	MicroSD module + 8GB card	~$8	Log raw data at 500Hz for offline analysis
Battery	LiPo 3.7V 2000mAh + TP4056	~$15	Wearable power for walking trials

PHASE 03 — Simulated Knee Joint

Connect the motor to a 1:1 mechanical replica of a human knee. Drive it with gait data captured in Phase 2. When this mechanical leg tracks a walking cycle correctly — under impedance control — you are ready for Phase 4. Control loop latency target: under 5ms end-to-end.

Component	Part	Cost	Notes
Frame	80/20 1" aluminum extrusion	~$100	Vertical leg mock-up with pivot joint
Knee Pivot	Flanged pillow block bearing 12mm	~$25	Zero-backlash coupling to motor shaft
Load Cell	50kg S-type + HX711 amp	~$22	Measure actual torque output, validate commands
Current Monitor	INA226 I2C power monitor	~$10	Real-time power consumption → battery sizing
Leg Segments	Aluminum flat bar 1"×1/4"	~$20	Thigh + shank fabricated from hardware store stock

PHASE 04 — Wearable Single-Joint Assist

The first device that goes on a body. A powered knee orthosis using the AK80-9 to provide assistive torque — not walking for you, but assisting where your own muscles are already trying. Safety gate: Phases 1–3 must be complete with 4+ weeks of stable operation before this phase begins. Katia present for all wearable sessions. Dr. Rosenthal signed off.

Component	Part	Cost	Notes
Second Actuator	CubeMars AK80-9 (left leg)	~$500	Bilateral is safer than unilateral for ataxia
Battery	48V 20Ah wearable LiPo pack	~$250	Sized for 2hr walking sessions
Brace Frame	KAFO modified or custom carbon	~$1,000	Structural foundation for the actuator mount
RF E-Stop	Wireless kill switch handheld	~$75	In-hand at all times during walking trials
Safety Harness	Chest harness + overhead tether	~$100	Mandatory for first 20+ wearable sessions

PHASE 05 — Bilateral Hip + Knee System

The full system: hip and knee actuation, left and right, with a unified control stack running gait phase detection from dual IMU/FSR sensor arrays. Four AK80-9 actuators. A full power electronics bay. This is what academic labs build with grad student teams. ExoLab will build it solo — which means it will take longer, and every decision will be deeply understood. Estimated timeline: 6–18 months beyond Phase 4.

Component	Est. Cost	Notes
2× Additional AK80-9 (hips)	~$1,000	Higher torque variant for hip flexion/extension
Power Electronics Bay	~$400	48V BMS, current distribution, emergency cutoff
Bilateral Frame	~$2,000	Carbon fiber + aluminum hybrid structural frame
Central Controller	~$200	Jetson Nano or Teensy 4.1 — real-time gait FSM
Full Sensor Array	~$300	6× IMU, 16× FSR, full bilateral coverage
Misc / Integration	~$1,000	3D printing, machining, wiring, iteration

⚡ DOWNLOAD FULL LAB PLAN — The complete ExoLab Build Plan document including detailed parts lists, control theory background, DSP mapping tables, workshop setup guide, and safety protocols is available as a Word document. Contact to request →

Technical Background

30 Years of DSP → Exoskeleton Control

The translation from digital signal processing to exoskeleton control is nearly one-to-one. Every skill developed over a 30-year engineering career maps directly to the core challenges of robotic mobility.

DSP Background

Real-time filter design

ExoLab Application

Kalman / Madgwick filter on IMU data for gait phase detection

DSP Background

PID loop tuning

ExoLab Application

Torque / impedance control on the AK80-9 actuator — same math, mechanical plant

DSP Background

Noise floor & SNR analysis

ExoLab Application

Heel-strike detection from force sensors buried in noisy floor contact signal

DSP Background

Fixed-point arithmetic & embedded C

ExoLab Application

Real-time control loop on STM32G4 — sub-5ms latency target

DSP Background

State machine design

ExoLab Application

Gait cycle FSM: heel-strike → loading → midstance → toe-off → swing

DSP Background

System identification

ExoLab Application

Characterizing the mechanical plant: joint stiffness, inertia, damping coefficients

DSP Background

Fourier analysis & spectral methods

ExoLab Application

SCA3 gait variability analysis — trunk sway frequency spectrum quantification

DSP Background

CEO / product leadership

ExoLab Application

Investment analysis of exoskeleton companies (Lifeward/LFWD, Wandercraft, Ekso)

Timeline

From Bench to Walking

A realistic timeline. Each phase is independently satisfying and produces real, documented results. No phase is skipped.

NOW · Spring 2026

Hardware Ordered. Software Stack Under Development.

CubeMars AK80-9 actuators ordered. Waveshare USB-CAN-A interface acquired. Python-CAN installed on Chromebook Linux (ARM64/Crostini). MIT Mini Cheetah protocol under study.

ACTIVE

PHASE 1 · Summer 2026

First Torque Command. First PID Loop. First Data.

Motor spinning under own control code. Position, velocity, and torque logged. Impedance controller tuned. E-stop tested. Lab bench established at Canby Road property.

~$800

PHASE 2 · Fall 2026

First Gait Dataset. SCA3 Signature Characterized.

IMU + FSR sensor rig worn during walking trials on property and W&OD Trail. Gait phase FSM validated. SCA3 trunk sway quantified. Dataset potentially shared with NAF research community.

~$225

PHASE 3 · Winter 2026–27

Mechanical Knee Tracks Real Gait. Control Latency Validated.

Simulated knee joint reproduces captured gait cycles under impedance control. Control loop latency measured and confirmed under 5ms. Load cell validates torque commands.

~$220

PHASE 4 · 2027

First Wearable Session. With Katia. With a Tether.

Bilateral knee assist device worn for the first time. RF e-stop in hand. Overhead safety tether. Dr. Rosenthal consulted. Every session documented. This is the milestone everything else points toward.

~$2,900

PHASE 5 · 2027–2028

Full Bilateral Hip + Knee System.

Four actuators. Full gait control stack. Walking outdoors on six acres in Leesburg, Virginia. Independent. On your own terms.

~$15,000

// Hardware Context

Exoskeleton Market Landscape

ExoLab's Layer 1/2 control systems are designed to run on top of commercial exoskeleton hardware — not replace it. The table below surveys the current market: consumer hip-assist devices and FDA-cleared medical exoskeletons.

Consumer / Fitness

Medical / Clinical

Company / Model	Price (USD)	Motor Count	Peak Power	Max Torque	Weight	Battery Range	Modes / AI	App / Interface	Use Case	Notes
▸ Hypershell — Consumer Fitness & Outdoor
Hypershell X Go Consumer	$899	2 hip motors	400 W	~16 N·m	~2.2 kg	15 km	6 modes, AI MotionEngine LIT	Hypershell+ app	Entry walking/hiking	IP54, -10°C, foldable. No charger included.
Hypershell X Pro Consumer	$899	2 hip motors	800 W	32 N·m	~2.2 kg	17.5 km	10 modes (Walk, Run, Stairs, Hills…), AI MotionEngine	Hypershell+ app	Hiking, cycling, mixed terrain	IP54, -20°C. 2 ms response. Carbon fiber + aluminum frame.
Hypershell X Carbon Consumer	$1,299–1,599	2 hip motors	800 W	32 N·m	1.8 kg	17.5 km	10 modes, AI MotionEngine	Hypershell+ app	Hiking, extreme terrain	Carbon fiber + titanium alloy. 4,000 km durability rating.
Hypershell X Ultra Consumer	$1,799–1,999	2 hip motors	1,000 W	~22 N·m	~2.3 kg	30 km	12 modes, AI MotionEngine	Hypershell+ app	Long-distance hiking, daily use	IP54, -20°C. Titanium + carbon fiber. 12 sensors incl. barometer, gyro.
Hypershell X Pro S NEW 2026 Consumer	$999	2 hip motors	800 W	18 N·m	~2.1 kg	17.5 km	HyperIntuition™ AI (0.31s sync), TÜV Rheinland verified	Hypershell+ app	Lighter outdoor activity	Launched May 2026. Soft package. Max 20 km/h.
Hypershell X Max S NEW 2026 Consumer	$1,499	2 hip motors	1,000 W	22 N·m	~2.2 kg	30 km	HyperIntuition™ AI, 36× processing leap	Hypershell+ app	Heavy outdoor / load carry	Titanium alloy waist/back. SpiralTwill 3000 carbon fiber. Max 25 km/h.
Hypershell X Ultra S NEW 2026 Consumer	$1,999	2 hip motors	1,000 W	22 N·m	~2.2 kg	30 km × 2 batteries	HyperIntuition™ AI, 0.31s intent sync	Hypershell+ app	Elite outdoor / search & rescue	3D-printed titanium hip tube. 0.7 mm wall carbon. ↓HR 42%, ↓O₂ 39%.
▸ DNSYS — Consumer Fitness & Mobility
DNSYS X1 Carbon Consumer	$999–1,099	1 hip motor	900 W (1.2 HP)	40 N·m	1.6 kg	20 km / 7 hr	AI intent prediction, adaptive learning, dual-core 240 MHz	DNSYS app (iOS & Android)	Hiking, running, daily mobility	3s battery swap. 9 safety modules. USB-C PD fast charge.
DNSYS X1 Carbon Pro Consumer	$1,899	1 hip motor	900 W (1.2 HP)	40 N·m	1.6 kg (actual ~2.2 kg)	40 km (2 batteries)	AI intent prediction, regenerative mode, 9 safety modules	DNSYS app	Heavy hiking, workout, running	Titanium alloy + carbon fiber. 3s battery swap. Max speed 27 km/h.
▸ AstroShell — Consumer Fitness
AstroShell Alpha 1 Consumer	$1,099	2 motors (est.)	1,000 W peak	40 N·m continuous	2.0 kg	24 km	AI Active System, adaptive assist	Companion app (est.)	Hiking, walking endurance	Aerospace magnesium alloy. Swappable "pocket" batteries.
▸ Ascentiz — Consumer Modular / Open-Source Platform
Ascentiz H1 Pro (Hip Module) Consumer Open-Source BodyOS	$1,049 Early backer $699 · Kickstarter #1 funded exo	1 hip motor (quasi-direct-drive)	900 W (1.2 HP)	36 N·m peak	1.75 kg (w/o battery)	~78 Wh battery	AI Motion Cortex, 10+ motion scenarios, 0.2s recognition	Companion app + open-source BodyOS SDK	Hiking, running, daily mobility	iF Design Award 2026. 35% effort reduction. Folds to A4. ⚡ BodyOS = ExoLab integration opportunity.
Ascentiz K1 Pro (Knee Module) Consumer Open-Source BodyOS	$1,149 Early backer $799	1 knee motor (cable-drive)	900 W (1.2 HP)	48 N·m peak	~2.25 kg (w/o battery)	~78 Wh battery	AI Motion Cortex, 10+ motion scenarios, 0.2s recognition	Companion app + open-source BodyOS SDK	Endurance, load-bearing, joint support	Cable-drive optimized for knee biomechanics. Supports up to 216 lbs load.
Ascentiz H+K Bundle Consumer Open-Source BodyOS	$1,498 Early backer $1,298	2 motors (1 hip + 1 knee)	900 W (1.2 HP)	36 N·m (H) / 48 N·m (K)	1.75–2.25 kg per module	~78 Wh per module	Full Ascentiz AI Motion Cortex; modules swap one at a time via Exo-Belt hub	Companion app + open-source BodyOS SDK	Full-activity coverage — switch hip/knee per terrain	World's first modular exo system. BodyOS enables custom control layer development.
▸ Lifeward (formerly ReWalk Robotics) — FDA-Cleared Medical
Lifeward ReWalk 7 Medical FDA Cleared	~$75,000–95,000 Medicare reimbursable; $94,617 CMS rate, 20% copay	4 motors (2 hip, 2 knee)	N/A	Not published	~23 kg (51 lbs)	Session-based	2 customizable walking speeds, cloud connectivity, smartwatch display	MyReWalk app, crutch control, smartwatch	SCI T7–L5, home & community ambulation, stairs & curbs	FDA cleared March 2025. First device with FDA stair clearance.
▸ Ekso Bionics — FDA-Cleared Medical
Ekso Bionics Ekso Indego Personal Medical FDA Cleared	~$75,000–95,000 Medicare, VA, workers comp coverage	4 motors (2 hip, 2 knee)	N/A	Limited (BLDC flat motors)	~14 kg (31 lbs)	Session-based	Wireless software control, individualized gait settings	iOS & Android wireless app	SCI T3–L5, home & community; NO stair clearance	Lightest medical exoskeleton. Modular 5-piece design. Carbon-fiber thermoplastic.
Ekso Bionics EksoNR Medical FDA Cleared	~$100,000+ Clinical/rehab centers only	4 motors (2 hip, 2 knee)	N/A	Not published	~20 kg (44 lbs)	Session-based	Multiple gait modes, stroke/SCI/ABI/MS modes	iOS app (therapist-controlled)	Rehab only: stroke, SCI, ABI, MS	Only exoskeleton FDA cleared for ABI and MS. Not for home use.

Engineering theFuture of Walking

A DSP Engineer Who Needs an Exoskeleton

Walking Again — By Engineering

The ExoLab Build Plan

PHASE 01 — Benchtop Motor Control

PHASE 02 — Gait Sensor Platform

PHASE 03 — Simulated Knee Joint

PHASE 04 — Wearable Single-Joint Assist

PHASE 05 — Bilateral Hip + Knee System

30 Years of DSP → Exoskeleton Control

From Bench to Walking

The ExoLab Reading Stack

Exoskeleton Market Landscape

Collaborate with ExoLab