The mastectomy bra (M-bra) serves as an essential rehabilitative product for individuals who have undergone breast cancer surgery. This study aimed to develop an ergonomic design method for M-bras that addresses both the physiological and psychological needs of post-mastectomy breast cancer patients. Over 270 M-bras with diverse design options were collected from online markets, and more than 100 post-mastectomy patients participated in an online survey to rank their preferences regarding eight M-bra components and 19 design options. An orthogonal experimental design was applied to reduce the vast array of design combinations to 20 M-bra test samples. The Pleasure-Arousal-Dominance (PAD) emotion model and the Self-Assessment Manikin (SAM) scale were then used to collect PAD scores from 40 patients evaluating these test samples. Extreme difference analysis was conducted to evaluate the significance of the M-bra components and identify combinations that generated the highest and lowest PAD levels. Based on the PAD scores, 11 samples were categorized as "delighted" or "relaxed" M-bras due to their positive emotional polarity. Linear regression analysis showed strong correlations between the design options and PAD scores, with R2 values of 0.962 for P, 0.819 for A, and 0.949 for D. A backpropagation neural network was developed to predict PAD values for various M-bra design options, achieving prediction errors of 8.06% for P, 6.15% for A, and 13.29% for D, demonstrating satisfactory performance given the subjective nature of the evaluations.
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