Sci-fi fans are likely well-versed in the benefits of the exoskeleton. Most often depicted as a form of performance-enhancing suit, exoskeletons not only protect their wearer but are capable of enhancing power, strength, and come equipped with weaponry to be used against enemies.
In Iron Man, Tony Stark’s suit is powered by an arc reactor, enabling him to carry immense weight. It’s fitted with guns, hand-mounted repulsers, and a chest beam. James’ Cameron’s Avatar features the Amplified Mobility Platform, which is used by the RDA Corporation for combat and equipped with an autocannon plus an enormous knife. In Edge of Tomorrow, which sees humanity battling against an alien invasion, soldiers wear Combat Jackets, which enable them to run faster and carry heavy weapons into battle.
These fictional examples are all a type of “powered” exoskeleton. But in the real world, there are two main categories:
- Powered exoskeleton – Fitted with motors or actuators, these exoskeletons are used to amplify a person’s strength.
- Passive exoskeleton – These are not fitted with motors or actuators but are used to support the body and redistribute weight and physical stress.
What Are the Benefits of Exoskeletons in Manufacturing?
For decades, exoskeletons have been used in medicine to assist patients with mobility, proving beneficial for paraplegics, amputees, and stroke or spinal cord injury survivors.
However, in recent years there has been an uptick in the use of exoskeletons within other industries (including manufacturing) where workers are often required to carry out repetitive and strenuous physical labor. The benefits of exoskeletons in this environment include:
- Employees are able to carry greater loads, for longer periods, in strenuous positions without feeling strain or fatigue.
- The rate of employee injury is reduced.
- An aging workforce, which is a real concern for the manufacturing industry, can continue performing physical labor later in life than might otherwise be possible.
- Increased efficiency and productivity.
- They negate the need for expensive robots or automation solutions, augmenting human performance rather than replacing it.
How Are Exoskeletons Used in Industrial Settings Today?
Ford’s EksoVests
Ford partnered with Ekso Bionics to deploy its EksoVests to 15 Ford plants around the world. The vest works by elevating and supporting an employee’s arm, providing 5-15lbs of lift assistance per arm when the springs are activated. This is an enormous help for workers on the assembly line who lift their arms an average of 4,600 times per day. Since introducing the vest, Ford has observed an enormous decline (up to 83%) in plant injuries.
Hyundai’s VEX
Last year, Hyundai Motor Group announced its new Vest Exoskeleton (VEX), targeted at its production-line workers whose job includes bolting the underside of vehicles and attaching exhausts. Weighing up to 42% less than competing products, the VEX is worn like a backpack, enhances employee productivity, and reduces fatigue. It works by imitating the movement of human joints to boost load support.
U.S Army’s Use of the Onyx
In 2018, the U.S. Army awarded a contract to Lockheed Martin for its powered exoskeleton, the Onyx. Onyx is a lower-body exoskeleton worn on the leg that employs electro-mechanical knee actuators, sensors, and AI to boost endurance and strength.
Sarcos Robotics’ Guardian XO
At the end of last year, Sarcos Robotics unveiled the Guardian XO, the world’s first battery-powered industrial robot that combines human intelligence and judgment with the power and endurance of machines. While most exoskeletons to date have targeted isolated areas of the body, the Guardian XO is a full-body suit that augments a wearer’s strength, boosts productivity and reduces injury, without restricting freedom of movement.
Sarcos exoskeleton is targeted at the military but could have a wide range of applications in manufacturing, addressing skilled labor shortages and occupational safety.
What Does the Future Hold for Exoskeletons in Manufacturing?
Widescale adoption is still some way off as companies wait for more concrete data on the suits’ ROI. Passive suits are likely to hit the mainstream first because they are more affordable and less technologically complex. It’s also feasible that the exoskeleton market will progress to a service-based model, making it more affordable for industrial businesses.
It’s predicted that global exoskeleton revenues will reach $5.8 billion by 2028, with ABI research predicting industrial exoskeleton revenue will experience a compound annual growth rate of 39.5% (hitting $2.9 billion) by this time.
