This project aims to develop a novel light-weight hip protective device for at-risk older adults. Specifically, based on Asian body size and pelvis shape, a comfortable, and breathable hip protector is developed through 3D-printing technology, making the individuals impervious to fall-related hip fractures. Through optimization of pad thickness, surface area and hardness via designing lattice structure, the new 3D-printed protectors can achieve greater protective value (force attenuation) and has a higher degree of user acceptance and adherence at a reasonable cost compared to traditional one.