The rapidly advancing fields of statistical modeling and machine learning have significantly enhanced data-driven design and optimization. This paper focuses on leveraging these design algorithms to optimize a medical walker, an integral part of gait rehabilitation and physiological therapy of the lower extremities. To achieve the desirable qualities of a walker, we train a predictive machine-learning model to identify trade-offs between performance objectives, thus enabling the use of efficient optimization algorithms. To do this, we use an Automated Machine Learning model utilizing a stacked-ensemble approach shown to outperform traditional ML models. However, training a predictive model requires vast amounts of data for accuracy. Due to limited publicly available walker designs, this paper presents a dataset of more than 5,000 parametric walker designs with performance values to assess mass, structural integrity, and stability. These performance values include displacement vectors for the given load case, stress coefficients, mass, and other physical properties. We also introduce a novel method of systematically calculating the stability index of a walker. We use MultiObjective Counterfactuals for Design (MCD), a novel genetic-based optimization algorithm, to explore the diverse 16-dimensional design space and search for high-performing designs based on numerous objectives. This paper presents potential walker designs that demonstrate up to a 30% mass reduction while increasing structural stability and integrity. This work takes a step toward the improved development of assistive mobility devices.

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