Exoskelett

What is an exoskeleton?

An exoskeleton is a body-mounted structure consisting of frames, joints, and support elements that absorbs or transfers forces, thereby reducing the muscular load on the wearer. The term originates from biology, where it describes the rigid outer shell of arthropods – in the workplace, it refers to wearable support systems for the human musculoskeletal system. Exoskeletons are designed for employees performing repetitive or physically demanding tasks: order pickers, packers, staff in goods receiving, or dispatch areas.

Passive and active systems compared

In logistics practice, two main designs are distinguished:

• Passive exoskeletons use springs, elastomers, or gas pressure springs to store and release forces. They require no battery or control electronics, making them lighter, lower-maintenance, and more cost-effective. Typical applications include back exoskeletons for bending and lifting, as well as shoulder and arm supports for overhead work.
• Active exoskeletons feature motors, actuators, and sensors along with a control unit. They can dynamically adjust the level of support, but are heavier, more expensive, and dependent on charging cycles. In intralogistics, they remain less common; their primary focus lies in rehabilitation and industrial heavy-load scenarios.

For typical warehouse and order-picking environments, passive back and shoulder exoskeletons currently dominate the market – though the range of offerings is growing rapidly and the boundaries between categories are becoming increasingly fluid.

Key considerations for implementation

Whether an exoskeleton delivers practical benefit depends heavily on the fit between the device, the task, and the individual. The following aspects are relevant when selecting and introducing a system:

• Task analysis: Not every task benefits equally. Repetitive lifting from a squat position, overhead assembly, or prolonged standing are typically well-suited scenarios; highly dynamic or confined environments may limit suitability.
• Acceptance and training: Employees will only wear exoskeletons consistently if they perceive them as a relief rather than a hindrance. Acclimatization periods, employee involvement, and regular feedback are critical.
• Hygiene and adjustment: In areas with rotating users – such as multi-shift operations – cleaning, size adjustment, and sweat absorption present practical requirements that the system must meet.
• Occupational safety and standards: The legal classification of exoskeletons as work equipment or personal protective equipment varies by vendor and system and should be assessed on a case-by-case basis. A harmonized European standard for workplace exoskeletons is still under development.
• Total cost of ownership: In addition to the per-unit acquisition cost, training effort, maintenance intervals, spare parts availability, and potential downtime must be factored in.