Podcast: 4 myths about occupational exoskeletons

Conversations about worker safety often revolve around automation and robotics, but one emerging technology is reshaping the discussion in a more practical way: industrial exoskeletons. In this episode of Great Question: A Manufacturing Podcast, New Equipment Digest's Editor-in-Chief, Laura Davis, breaks down the most common myths and misconceptions surrounding occupational exoskeletons—and why they're becoming an increasingly relevant tool for reducing strain and preventing injuries on the plant floor.

This episode is based on an article written by Matthew Yandell, PhD, CIO and cofounder of HeroWear. Whether you're evaluating ergonomics solutions, exploring wearables, or simply trying to separate fact from fiction, this discussion offers a grounded, practical perspective on one of the industry's most talked-about innovations.

Below is an excerpt from the transcript:

Occupational exoskeletons—which I will sometimes refer to as exos moving forward—are wearable assistive devices. And the whole point is to reduce physical strain, especially for workers who bend, lift, push, and pull all day long. And we know that that strain is a big deal, especially when it's repetitive. According to Liberty Mutual’s 2024 Workplace Safety Index, overexertion is the number one cause of worker injuries in the U.S. across logistics, manufacturing, retail—you name it.

These are injuries that cost companies millions and take a serious toll on workers and their daily lives and well-being. And that’s exactly why exos were created.

But because this technology is still relatively new in workplaces, a lot of misinformation is floating around—some accidental, some driven by oversimplification or hype. So let’s walk through four of the biggest myths and what the facts actually tell us.

So myth number one is that exoskeletons are bulky, uncomfortable, and limit your range of motion.

I even thought this one was true a few years ago because the only exos I had seen were big mechanical suits that were for very specific applications. And it's no wonder that other people still think that when they've only been introduced to exos through sci-fi portrayals. In reality, though, there are different categories of exos, and they’re not all built the same.

Structurally, there are two categories: rigid and soft. Rigid exos, which do have a firm frame, can be bulky and limit movement depending on the use case. Soft exos, or “exosuits,” use flexible, textile-based materials. These are designed for comfort, mobility, bending, twisting—all the things that repetitive movement requires.

Then you have two types of power sources: passive and powered.  Passive exos, which are sometimes called elastic exos, use springs or elastics, which make them lightweight and great for long shifts. And then powered exos have motors or batteries. These can lock you into certain postures for sustained work, but they are heavier and bulkier as a result.

So the idea that all exos are uncomfortable or restrictive is not true at all.

The real key is matching the right exo to the right task—and making sure workers can pilot it, adjust it, and offer feedback before it's rolled out.

Now let's move on to the second myth. Myth number 2 is that exoskeletons give you superhuman strength. And this is the sci-fi myth in full force. Exos are not turning your warehouse team into superheroes. That's not the point of them.

Exoskeletons are not designed to help workers lift heavier loads. They are designed to reduce the strain of lifting the loads they already handle. I'm going to say that again: Exoskeletons are not designed for heavier loads. They're designed to reduce the strain of loads. Most back-assist exos reduce about 10 to 40% of the load on the worker’s spine. And trying to provide more support than that becomes uncomfortable and counterproductive.

What workers do notice is less fatigue, less strain, and a lower risk of musculoskeletal disorders. That means they feel better at the end of the day—not that they're ready to bench-press a forklift.

Which brings us to myth number three, which is that exos are one-size-fits-all. This one is somewhat true, but also false. Workers come in every shape and size, and exos don’t magically adjust themselves to every body type. Some types are adjustable, and some aren't.

Soft exos—remember these are the ones that use flexible, textile-based materials—generally fit more people because textiles are easier to tweak. The rigid or motorized designs usually have more limitations.

If you're going to choose an exoskeleton, you should be looking for one that is adjustable, offers modular components, offers different fit options for all body types, and, most importantly, offers worker comfort testing. If it doesn't fit right, it won't work right and cause more harm to the body. It also won't be adopted by your workers. Now, this is if you're trying to fit an entire team with exos. If you have a different application that would require a one-off or rigid exo, that's a different story.

And that brings us to our final misconception—one that often stops companies before they even get started.

Myth number four is that it's too hard to implement an exoskeleton program. This is a big concern for leaders and safety teams, and it's a valid concern.

Any new program can feel overwhelming—especially one that’s wearable, personal, and tied to worker health. But hard doesn't mean impossible. Right now, there are plenty of companies that have and are successfully deploying exos at scale, with high adoption rates and good ROI.

The difference between a successful and unsuccessful deployment is training, for both workers and supervisors; clear expectations; good change management; and real and honest communication about why the tech matters.

Workers are often skeptical at first, which is normal, and it's ok. But the moment they realize how well it reduces their strain, helps them feel better after a shift, and doesn’t hinder their work, they usually become some of the biggest advocates.

For leaders, once the safety benefits are clear, the productivity lift and cost savings become pretty hard to ignore.

And with that, we've tackled the major misconceptions that tend to hold this practical tool back. When you strip away the myths, the picture becomes much clearer: exoskeletons can play a pivotal role in reducing injuries when they're deployed thoughtfully.

Safety technology is evolving quickly, and exoskeletons are one of the most promising tools we have for injury reduction—especially in physically demanding industries.

The best thing companies can do is stay educated: Research the types, the benefits, the limitations, and how to implement them well. The right exo, rolled out the right way, can make a meaningful difference for workers and workplaces.

If you want to dive deeper into case studies or the research behind exoskeleton adoption, I've included the link to the original article in the podcast description.

That's all for the show today. I hope this helps bring some clarity to where exo technology currently stands. Stay safe, stay informed, and thank you so much for listening. I'll see you next time.