DFMEA-based risk mitigation and validation of a controlled descent rescue device

<i>Objectives.</i> Controlled fall rescue devices (CFRDs) are increasingly used as personal evacuation tools for emergency escape from high-rise buildings, industrial structures and fire-prone environments. Despite their growing adoption, the safety performance of these devices depends heavily on reliable mechanical operation, ergonomic suitability and well-defined risk mitigation measures. <i>Methods.</i> This study systematically evaluated the potential hazards associated with a centrifugal brake-based controlled descent device and proposes a comprehensive risk mitigation framework to enhance operational safety. Hazard identification and risk analysis were conducted using structured engineering approaches, including design failure mode and effects analysis (DFMEA), ergonomics assessment and material suitability review. <i>Results.</i> Critical risks such as over-speed descent, thermal stress on brake components, spring malfunction, rope wear and user device interaction errors were identified and addressed using specific engineering controls and preventive strategies. <i>Conclusion.</i> This study provides detailed mitigation techniques to ensure consistent braking performance, improve mechanical integrity and enhance user safety during emergency descent. The outcomes contribute to safer deployment of CFRDs in occupational and residential environments and support improved regulatory and design guidelines for emergency-descent systems.