# IRON-DAD — Initial risk and test register D01

**Open engineering register, not a completed hazard analysis or FMEA. No likelihood/severity scores or safety certification are asserted.**

| ID | Hazard / unresolved issue | Intended design response | Evidence required | Status |
|---|---|---|---|---|
| R01 | Cannot independently exit; unreachable closure | Accessible manual closures and independent wearer release; stand for normal dressing only | Actual glove/force/trajectory trials, seated and power-off removal, controlled emergency plan | OPEN: P01 point reach is insufficient |
| R02 | Spring remains energized after stop/disconnect | Guarded retained springs; independent escape; controlled unloaded servicing position | Reviewed mechanism, stored-energy isolation and off-body trials | OPEN: original elbow arrangement rejected |
| R03 | Panel or frame traps soft tissue | Movement accommodation, clearance, edges and guarded interfaces | Continuous path study followed by unloaded fit checks and physical trials | OPEN: original collisions retained |
| R04 | Pressure, numbness or impaired breathing | Broad adjustable padding, no hardware intrusion, wearer feedback | Real measurements, pressure/comfort checks in motion | OPEN: estimated human only |
| R05 | Heat buildup or blocked fan | Ventilation, accessible manual opening, local indications; stop activity | Off-body airflow/heat tests, blockage trials, reviewed stop criteria | OPEN: no temperature threshold selected |
| R06 | Battery short, damaged insulation or overheating | Protected commercial pack, coordinated protection, accessible total disconnect | Selected ratings, fault tests, thermal review, retention/venting checks | OPEN: no electrical BOM |
| R07 | Motor stalls or restarts unexpectedly | Separate accessory branch; physical limits, local enable, deliberate restart, disengagement | Physical fault injection and measured forces; guard verification | OPEN: no motor or firmware |
| R08 | Display loss, occluded sensor or stale reading | Direct sight, physical controls and escape independent of AR | Donor-device optical fit and failure checks | OPEN: no headset owned |
| R09 | Cable snag, abrasion or connector supports panel weight | Controlled dynamic loops, strain relief, service sequence, edge protection | Full-range and repeated-cycle harness tests | OPEN: routing reservations only |
| R10 | Pack/module or casting detaches | Reviewed attachment load, retained hardware, appropriate material/inspection | Off-body static/fatigue/retention tests for real parts | OPEN: coupon is nonstructural |
| R11 | Loss of balance or blocked foot release | Independently reviewed ground path, foot interface, stable dressing support | Ground-load and movement tests with supervision | OPEN: no validated load path |
| R12 | False confidence from attractive model or zero collisions | Visible scope labels, recorded failures and separate physical gates | Evidence audit before any claim or fabrication release | ACTIVE presentation measure; physical risk unresolved |
| R13 | Loss of all electrical cooling after total disconnect | No electrical dependency for escape; clear distinction from motion stop | Full power-off exit test; no wearable load initially | OPEN |
| R14 | Hard retention/gearbox does not release on power cut | Manual disengagement independent of software | Mechanical release under realistic loads on bench | OPEN |
| R15 | Prototype mistaken for protective armor | No ballistic, impact, respiratory, fire, fall-arrest or electrical-PPE rating | Clear labeling and no use as certified protection | ACTIVE scope limit |

No prototype should be worn under substantial load based on this register. It identifies work, not authorization to proceed. Draft wiring/motor concepts do not remedy the missing joints or opening conflicts in P01.4.