Physical interaction pressure between wearers and back exoskeletons during repetitive lifting

Abstract

Lower back pain is a widespread occupational hazard among construction workers, causing health and economic burdens. Industrial back exoskeletons provide support to reduce spinal strain, but excessive interaction pressures-the localized contact pressures between wearer and device-limit applicability. This study quantifies interaction pressure magnitude and distribution for four back exoskeletons (Laevo FLEX, IX BACK, SV Exosuit, Laevo V2.5) during controlled repetitive lifting representative of construction tasks. Pressure sensors recorded at upper body (chest for Laevo V2.5; shoulder for others), thigh, and lateral waist (excluding SV Exosuit). Lightweight active SV Exosuit produced the lowest standing pressures. Waist belts offload thigh pressures and enhance stability but create high localized pressures and shift torque to the waist. Chest interfaces distribute loads yet can restrict breathing and cause fit issues. Thigh comfort depends on pad size, strap design, and waist configuration. Findings identify design trade-offs and guide targeted optimizations to reduce pressures and improve comfort.