Abstract—To help the neurological patients regain mobility to their impaired arms, a robotic rehabilitation device (called RSP-60) is developed for this purpose. This paper presents the development of a lightweight portable robotics elbow brace device that fits snugly onto Asian patients with weak upper-limb impairment for repetitive elbow flexion and extension rehabilitation without the presence of the therapists. The device is integrated with surface electromyogram (S-EMG) sensors for assistive & assessment purpose, LabVIEW based interface and built in signal processing module for interactive actuation of device. A secondary anthropometric data are mainly collected from Asian subjects with age ranges of 18 to 60 years & above and statistically analysed to use as a design guideline. Pilot clinical trial was carried out with post-stroke patients to access a safety aspect of using the device and evaluate the performance of the device in terms of a valuable therapist’s time saving, usage of bio‐feedback for active assistive & assessment, usability and users’ perception towards using robotics device in rehabilitation. Both experimental condition data and qualitative results are presented and a pain numeric rating scale (NRS) is used for pain assessment tool.