A chance encounter at church sparked an engineering project that has since combined computer programming, health sciences and 3D printing into a working prototype for a Baldwin Preparatory Academy senior.

According to a news release from the school, Carlos Alejo Flores, a student in Baldwin Prep’s Health Sciences pathway, designed and built a wireless-controlled prosthetic hand that uses a 3D printer, an ESP32 microcontroller and a smartphone app to control its movements.

The project began the summer before Flores’ junior year when he met a man at his church who had undergone a below-the-knee amputation. Although the man had a prosthetic leg, he continued to depend on a cane to walk. The encounter prompted Flores to consider how technology could improve prosthetic devices and the experiences of the people who rely on them.

With an existing background in engineering, Flores set out to develop his own solution. His experience with computer-aided design (CAD), soldering, microcontrollers, computer logic and prototyping provided a foundation for the project. His father, an electrical engineer, also helped foster his interest in the field.

Flores initially built a cardboard model featuring a claw-style grip. He used the prototype to explore how much movement and grip strength would be necessary for the hand to pick up different objects. He then translated those calculations into computer code to control the device.

The finished design uses an ESP32 microcontroller connected to servo motors to direct the hand's movements. Flores also developed a system that allows the prosthetic to operate wirelessly through a smartphone app.

Getting from the initial concept to the completed prototype required 14 design revisions. After refining the design and finalizing the programming, Flores 3D-printed the individual components and assembled the device, bringing together engineering, technology and health sciences in a single project.

“This is exactly the type of learning experience we want our students to have at Baldwin Prep,” Mary LaCoste, assistant principal at Baldwin Preparatory Academy, said in the release. “Carlos has taken what he has learned in the classroom and applied it to a real-world problem, combining health sciences, engineering, technology, and problem-solving to create something of his own. We are incredibly proud of the initiative and creativity he has demonstrated.”

What started as a personal engineering project eventually became a competitive entry in the HOSA Medical Innovation competition. Flores partnered with fellow Health Sciences student Emily Locke, and the pair was among eight teams to qualify for the Alabama HOSA State Leadership Conference.

His coursework has helped expand his understanding of the human body and how its systems work together, further fueling his interest in biomedical engineering. The HOSA competition also pushed the students to look beyond the mechanics of prosthetics and consider broader challenges, including healthcare costs, utilization and accessibility.

The prosthetic project is not Flores' only recent achievement. He was recently named a National Merit Semifinalist, an academic distinction earned by fewer than 1% of high school seniors in each state. The recognition is based on students' performance on the PSAT/NMSQT during their junior year.

Flores also serves as president of Mu Alpha Theta, a mathematics honor society, and vice president of Phi Theta Kappa, an honor society at Coastal Alabama Community College. He is a member of both the National Honor Society and National Technical Honor Society.