Exoskeleton technologies: finding a fit in tomorrow’s workplace

For companies and workers to factor exoskeletons into their future, we need proof that they’ll work in the real world. Enterprises need to begin experimenting now — and innovators are ready to assist with the heavy lifting that lies ahead.

In our last edition of Innovation Re:Imagined, I shared why I believe exoskeleton technologies will play a transformational role in improving the physical wellbeing of millions of people and help ease the debilitating pain-related problems affecting workplaces worldwide.

But first, we need to get it to the real world: there are several good reasons why these wearable devices have not yet become regular fixtures across our society or the global business landscape.

In this edition, I’ll focus on the exoskeleton’s still-evolving role in the workplace of tomorrow — sharing insights gathered during EY testing efforts, addressing some of the barriers currently impacting marketplace adoption, and discussing how piloting exoskeletons in the workplace today will help businesses leaders discover what’s possible in the not-too-distant future.

Exoskeleton testing efforts from EY

EY Global Innovation teams recently tested two exoskeleton models created specifically for the workplace, and designed to operate in very different ways:

·?????? German Bionic’s Cray X model is an active-type exoskeleton designed to protect a user’s back while completing tasks like bending to pick up and put down heavy objects. It can provide the user up to 66 pounds of support while lifting and walking. Simply put, that means a worker who is wearing an exoskeleton and carrying a 99-pound box will feel as though the item only weighs 33 pounds.

In our testing, we experienced how the Cray X could help workers with repetitive heavy lifting, but also found that they would need time to adapt and train their bodies to use it. It restricts movement which, in our experience, can cause initial muscular stress and discomfort. The Cray X model did feature sensors and smart features that allow it to adapt to the specific way a worker moves.

·?????? ErgoSanté’s Hapo MS and PH models are soft, lightweight, passive-type exoskeletons. The Hapo MS exoskeleton supports a worker’s arms and shoulders to reduce the strain of performing repetitive work where the arms are held in front or above the body — ideal for mechanics working overhead on a car chassis. It provides up to 13 pounds of support. The Hapo PH exoskeleton is designed to support a user’s back and provides about 30 pounds of assistance.

In our experience, the Hapo exoskeleton models didn’t interfere with the user’s natural movement as much as the Cray X, which made them more comfortable and easier to both wear and use. But there’s a trade-off — they couldn’t provide as much assistance as the Cray X.

Real world obstacles currently impacting widespread exoskeleton adoption

It’s clear that exoskeletons can significantly reduce physical loads on the body. However, there’s also evidence to suggest other risks can arise from their use. For example, reducing muscular stress in one area of the body can increase it in a different area or create risks through de-conditioning and weakening of muscles.

We also need to consider what happens to people’s behavior. Exoskeletons don’t suddenly give users superpowers — users can still suffer from severe muscle strain if the device enables them to move an arm or a leg beyond its normal range of motion. Increased reliance on exoskeletons could also undermine important risk management policies. By making users feel less vulnerable and less aware of potential threats, this could slow down their response to hazards.

Cost is currently another critical consideration because exoskeletons aren’t cheap. In 2022, the average selling price for a heavy-lift powered exoskeleton designed for lower body support in was $40,207, and $5,393 for a lighter-weight, passive exoskeleton of the same type, according to ABI research.

We need to get exoskeletons out of the lab and into the workplace

Despite these reasonable concerns hindering the immediate and widespread adoption of exoskeletons, there is general consensus on one point: without real-world field testing, we’ll never break through these barriers to create the kind of exoskeletons that can truly change workers’ lives.

To get there, we need businesses to begin actively piloting exoskeletons across their own workplaces. Testing an array of exoskeleton models in real work environments with a wide range of tasks — and performed by experienced workers for longer periods — will provide valuable field data that shows business leaders how exoskeletons can improve performance and help protect the health of their workers.

Equally critical, increased field testing is the only way that exoskeleton manufacturers will get the real-world feedback they need to iterate and improve on designs. Finally, workplace piloting efforts will also help companies establish their own realistic and accurate ROI calculations for their future investment in exoskeleton technologies.

Car manufacturers are leading the charge and have been successfully testing exoskeletons within their facilities as a solution for manual assembly tasks that are fast paced, highly precise, and physically taxing. Positive progress is also emerging in the health care sector through field studies, such as German Bionic’s joint research project with one of Europe’s largest university hospitals, the Charité in Berlin.

Lab research and early field tests to-date have clearly shown us that exoskeletons could ultimately be deemed worthy of being characterized as a “transformative technology” for people, businesses, and economies around the world. We firmly believe that they’re now mature enough to take into workplaces everywhere to explore their real-world potential.

I encourage business leaders to begin exploring how these remarkable devices may ultimately serve their organizations and, most importantly, enhance the safety and wellbeing of their workforce. Their efforts will help move us closer to a future when these wearable devices become an integral part of our everyday lives.

It’s the right time for us to take this game-changing technology outside of the lab, and step boldly into the future.

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The views reflected in this article are the views of the author and do not necessarily reflect the views of the global EY organization or its member firms.

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