Background The badminton lunge is a decisive yet injury-prone action that places substantial loads on the ankle, and toe-in, neutral, or toe-out orientations may alter joint mechanics and influence injury risk; however, evidence in sport-specific lunge contexts is scarce. This study quantified the biomechanical effects of different toe-orientations in badminton lunge landings using integrated motion capture, force measurement, electromyography, and finite element modeling. By uniquely combining EMG and FEA, the study provides evidence-based guidance for performance optimization and injury prevention. Methods Thirty male amateur badminton players performed right-lunge landings under three toe-orientations. Kinematic and kinetic data were collected using motion capture and force platforms. Muscle activation was assessed through surface electromyography and musculoskeletal modeling. A three-dimensional finite element model of the foot simulated Von Mises stress distribution. Statistical analyses included repeated measures ANOVA and statistical parametric mapping. Results Toe-out landings significantly reduced ankle eversion angles, eversion moments, anterior-posterior shear forces, and joint impulse (p < 0.001, p = 0.025, p = 0.047, p = 0.038). They also promoted smoother power output and greater anteroposterior center-of-mass displacement. Stress shifted from the rearfoot to the forefoot, accompanied by increased activation of the peroneal muscles and triceps surae. In contrast, toe-in landings produced higher eversion loading, stress concentration in the rearfoot, greater tibialis anterior activation, and restricted center-of-mass displacement. Conclusion Toe-out positioning lowered ankle load and rearfoot stress, improved stabilizing muscle activation and shock absorption, and facilitated center-of-mass control. Toe-in positioning elevated stress concentration and injury risk. Moderate toe-out angles were recommended to optimize footwork efficiency and protect joint health.
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