What is an Industrial Exoskeleton?

Industrial exoskeletons help you take on physically demanding tasks with less strain. These wearable devices support your body’s movements, making it easier for you to lift, carry, and repeat tasks without getting as tired. If you work in manufacturing, warehousing, or construction, you’ll find that exoskeletons can reduce injury risks and increase productivity. 

They’re a smart investment to keep you and your team safer and more efficient. With options ranging from simple passive models to advanced powered suits, you can find the right exoskeleton to meet your specific needs and make your workday easier​.

What Does an Industrial Exoskeleton Mean?

An industrial exoskeleton is a wearable tool that supports your body while you work. It helps you handle tasks like heavy lifting, repetitive movements, and awkward postures and overhead work by reducing strain on your muscles and joints. There are two main types: powered and passive. Powered exoskeletons use motors and sensors to boost your strength, while passive ones rely on mechanical parts like springs for support. You’ll see these exoskeletons in industries like manufacturing, warehousing, and construction, where they’re used to increase safety, lower injury risks, and improve productivity by enhancing concentration and work quality​.

How Does an Industrial Exoskeleton Work?

Industrial exoskeletons work by redistributing weight and adding support to key areas of the body. A passive exoskeleton, for example, might use springs to relieve strain on your lower back when you bend or lift. Powered exoskeletons go further by using motors to assist with heavy or repetitive tasks, reducing your fatigue and helping you work longer without risking injury. 

The S700 exoskeleton, specifically, is designed to reduce strain, which has the added benefits of increasing worker concentration and enhancing the quality of work performed. This leads to a safer and more productive work environment, as reduced strain and fatigue improve both physical well-being and task focus.

Why Use Industrial Exoskeletons?

1. Injury Reduction:

Exoskeletons are designed to support you during repetitive or heavy tasks. They reduce the strain on your muscles and joints, helping prevent common injuries like back pain and musculoskeletal disorders. By wearing an exoskeleton, you can work overhead, bend, and hold awkward postures with less risk of injury.

2. Enhanced Productivity:

Exoskeletons can improve productivity indirectly by helping to reduce physical strain, which may lead to fewer muscle-related discomforts and potentially fewer sick days. By supporting proper posture and alleviating stress on key areas like shoulders, these devices create a more comfortable work environment. This can result in improved morale and motivation, as workers feel physically supported, ultimately contributing to a steady pace and enhanced focus during tasks.

3. Enhanced Job Quality & Concentration:

Exoskeletons enhance job quality by reducing physical strain, allowing workers to maintain better focus and concentration. By redistributing weight from the shoulders to the hips, particularly in models with pneumatic support in the shoulder and arm areas, exoskeletons make tasks more comfortable and sustainable. This leads to improved task accuracy and consistency, ultimately supporting a high standard of work.

4. Worker Retention & Quality of Life:

Exoskeletons improve your quality of life by reducing physical strain. Many workers report feeling less fatigued and experiencing reduced soreness at the end of a shift. This support can help companies retain skilled employees by fostering a more comfortable and supportive work environment where workers feel valued.

exoIQ S700, an active exoskeleton designed to support and assist users in performing overhead tasks by providing ergonomic and mechanical aid, 2024

Types of Industrial Exoskeletons:

Active vs. Passive Exoskeletons:

Active exoskeletons use motors and sensors to boost your strength and support your movements. They’re perfect for tasks that involve heavy lifting or repetitive actions. Passive exoskeletons don’t use power; they rely on springs and mechanical parts to reduce strain, often making them lighter and simpler. While passive models can sometimes be more affordable, exoIQ offers an active model, the S700, at a competitive price of €3,500—lower than many passive options from other brands, such as the SUITX from Ottobock.

Functional Categories:

1. Back Support Exoskeletons: 

These exoskeletons focus on your lower back, reducing strain when you lift or bend. They’re ideal for jobs that involve frequent bending and heavy lifting​.

2. Upper Body & Arm Support: 

Designed for tasks with overhead or repetitive arm movements, these exoskeletons help reduce shoulder and arm strain. They’re common in manufacturing and construction​.

3. Full Body Exoskeletons: 

These offer full-body support, although they’re less common due to their size and cost. They’re useful for roles that need full-body assistance, like material handling.

4. Specialty Exoskeletons: 

Tailored to specific tasks, these exoskeletons might assist with tool holding or even add extra arms. They’re designed to meet unique needs in specialized roles​.

Example of Applications in Various Industries:

Manufacturing & Assembly:

In manufacturing, exoskeletons help you lift and handle repetitive tasks with less strain. “Automotive company Ford rely on exoskeletons to reduce physical stress on the assembly line (RobotReport, 2018)”. They support you with tasks like lifting parts, handling tools, and packaging, allowing you to work longer without fatigue. Exoskeletons also reduce the risk of injuries during repetitive tasks, which improves your overall productivity​.

Warehousing & Logistics:

Warehousing often involves heavy lifting, long shifts, and repetitive movements. Exoskeletons make these tasks easier by reducing strain on your body. Companies like Lowe’s use them to protect their employees during demanding workdays. You can use an exoskeleton for sorting, loading, and moving inventory—tasks where back and arm strain are common. The support helps you work more comfortably and safely, which means fewer breaks and injuries over time​.

Construction:

Construction sites present unique physical challenges, especially with overhead work and handling heavy tools. Exoskeletons can help you maintain better posture and reduce fatigue. For example, they support your back and shoulders when you’re lifting or operating heavy equipment, helping you stay safer on the job. You can also use them for tasks like drilling and securing beams, which require sustained arm effort. This reduces the risk of injury, allowing you to focus more on precision and efficiency​.

Top Brands & Models:

exoIQ:

exoIQ’s active models, like the S700, use electro-pneumatic systems to assist you with tasks at shoulder height. This specific model provides precise arm support with a capacity of up to 50N per arm, which is especially useful for tasks that need stability and control​.

Ekso Bionics:

Ekso Bionics offers the EksoVest, a passive exoskeleton that supports your arms during overhead work. It’s designed to reduce fatigue, letting you hold your arms up comfortably for longer. This model is commonly used in manufacturing, especially for tasks where you need steady, elevated arm support​.

German Bionic:

German Bionic’s Cray X is an active exoskeleton built for heavy lifting. It uses motors to reduce the strain on your back, making it ideal for tasks in warehousing. The Cray X is perfect if your job involves repetitive lifting over long shifts​.

Comau:

Comau’s MATE exoskeleton range focuses on passive support for your arms and shoulders. This model helps you manage repetitive arm movements with less strain, making it a great fit for assembly tasks that require endurance.

Other Notable Brands:

Levitate Technologies offers the Airframe, which helps relieve strain on your shoulders and neck. For full-body support, RB3D’s Hercule model is designed for heavy-duty lifting and intense physical tasks​.

Cost Considerations:

Passive Exoskeletons:

Passive exoskeletons cost between €4,000 and €6,000. They don’t have motors, which makes them simpler and more affordable. If you need a straightforward solution to reduce physical strain on your workers, a passive exoskeleton is a budget-friendly choice​.

Active Exoskeletons:

Active exoskeletons are more advanced and start around €8,000, with high-end models reaching up to €45,000. These models include motors and sensors to give you more power and precise support, ideal for tasks that involve heavy lifting or repetitive movements. However, some models, such as the exoIQ S700 priced at approximately €3,500, offer competitive pricing, making them a budget-friendly choice with active features. The price varies based on the features and complexity of the model​.

Leasing & Rental Options:

If buying outright doesn’t fit your needs, many suppliers offer leasing or rental options. Leasing allows you to try different models or increase the number of exoskeletons during busy periods. This gives you flexibility and access to advanced models without the upfront cost​.

To learn more about financing your automation solutions, check out this article: 

Financing Your Robot Solution

Implementation Challenges & Considerations:

Worker Training:

Training your team is essential for using exoskeletons effectively. Workers need to know how to wear, adjust, and operate the equipment safely. This training helps prevent misuse and ensures that everyone is comfortable and protected when using exoskeletons on the job​.

Comfort & Fit:

For an exoskeleton to be effective, it has to fit well. The design should allow natural movement and be comfortable for long hours. Look for models that can be adjusted to fit different body types, so each worker can use them without discomfort. Proper fit is key to ensuring your team stays productive and pain-free throughout the day​.

Maintenance:

According to exoIQ’s website, active exoskeletons generally require only an annual check to ensure long-term reliability. Components like motors, sensors, and batteries are usually robust enough that more frequent inspections aren’t necessary. Regular annual maintenance helps prevent unexpected downtime and keeps the equipment operating smoothly.

Choosing the Right Exoskeleton for Your Needs:

It’s important to match the exoskeleton type to your specific needs. Think about the tasks involved, the work environment, and any unique requirements. By selecting the right model, you’ll ensure the exoskeletons improve safety, comfort, and overall productivity​.

Conclusion:

Industrial exoskeletons are a smart investment for improving safety, employee retention as well as job attraction. They reduce strain, prevent injuries, and help your team handle tough tasks more efficiently. With various options to fit your needs—whether passive or powered—these devices can transform your workplace. Prioritizing proper training, comfort, and maintenance will ensure you get the most out of your investment. By adopting this technology, you’re creating a work environment where safety and efficiency support each other​.