This paper presents the design, development, and evaluation of a smart crutch prototype aimed at modernizing assistive mobility devices for individuals with physical impairments. The prototype integrates an ergonomic design that redistributes weight through the forearm to reduce wrist strain, enhance user comfort, and ensure optimal stability with a well-balanced center of mass. Structural analysis, performed using finite element modeling in SolidWorks, confirmed the durability and mechanical reliability of the 3D-printed ABS material under real-world loading conditions. The crutch incorporates sensor systems, including a 3-axis accelerometer, gyroscope, GPS, pulse oximeter, and Bluetooth module, to provide features such as fall detection, real-time posture correction, and continuous health monitoring. These sensors are managed by an Arduino Nano microcontroller, ensuring data acquisition and processing, as well as wireless communication with mobile devices. Patient trials indicated high levels of acceptance, with users reporting enhanced mobility, greater safety, and increased confidence due to the crutch’s health feedback and connectivity capabilities. The findings highlight the potential of integrating innovative sensor technologies and ergonomic design into assistive devices, offering transformative benefits in safety, functionality, and independence for users.