Purpose <p>Post-surgical joint rehabilitation is essential for restoring mobility, preventing complications, and improving quality of life. Conventional rehabilitation therapy either involves time-consuming, costly in-person hospital visits or rigid, component–based wearable systems developed using complex fabrication techniques or costly materials that reduce ease and comfort. In addition, the accumulation of e-waste over time is posing serious environmental concerns.</p> Methods <p>This study aimed to develop a post-surgical rehabilitation monitoring orthosis system using flexible, low-cost sensors derived from e-waste. Graphite was extracted from waste-drained cells, purified, and mixed with paint to prepare the conductive ink. This conductive ink was then used to fabricate the fractal electrode pattern on the paper substrate using a shadow mask, which simplified thefabrication process and improved scalability and reproducibility. The prepared sensor was then replicated in different dimensions for finger, wrist, elbow, and knee joints, and translated into a rehabilitation monitoring orthosis by seamlessly attaching the sensors to joint sleeves and a data acquisition system.</p> Results <p>The sensor demonstrated low hysteresis of 5.1%, excellent linearity (R = 0.99), high sensitivity (GF ≈ 245) and good dynamic performance, with fast response and recovery times of 200 ms and 290 ms, respectively. The sensor was also tested under repeated bending up to 1000 cycles, demonstrating stability over a long period. The sensor was then used to track post-surgery elbow joint rehabilitation using the designed tracking app.</p> Conclusion <p>Thus, the proposed orthosis system has the potential to make post-surgical rehabilitation more accessible, economical and enviorment friendly.</p>