A hand loss or severe impairment can significantly impact an individual’s quality of life by restricting essential daily activities and professional tasks. Traditional prosthetic solutions face challenges regarding cost, accessibility, and functionality, limiting their widespread adoption. This study presents an innovative approach to designing and developing a bionic hand prosthesis that integrates ergonomic principles, intuitive control, and sustainable manufacturing methods. The primary focus is affordability and usability, offering an accessible and adaptable alternative to conventional prostheses. The design process leverages CAD tools for precise modelling and simulation, ensuring structural accuracy and efficiency. Additive manufacturing uses biocompatible, cost-effective, and eco-friendly materials to balance durability, robustness, and comfort. The system enables precise control by integrating sensors such as inertial measurement units (IMUs), enhancing user experience and adaptability. The control system processes inputs to facilitate intuitive operation. Eliminating reliance on EMG expands the prototype’s applicability to a broader range of users, including those with minimal residual muscle activity. With its affordable and sustainable design, this prosthesis has the potential to provide access to functional prosthetic solutions, particularly in developing countries, ultimately improving the quality of life for individuals with upper limb disabilities.