FleXo: A Flexible Passive Exoskeleton Optimized for Reducing Lower Back Strain in Manual Handling Tasks

Musculoskeletal disorders, particularly low back pain, are some of the most common occupational health issues globally, causing significant personal suffering and economic burdens. Workers performing repetitive manual material handling tasks are especially at risk. FleXo, a lightweight (1.35 kg), flexible, ergonomic and passive back-support exoskeleton, addresses this by reducing lower back strain during lifting tasks while allowing full freedom of movement for activities like walking, sitting, or side bending. FleXo's design results from an advanced multi-objective design optimization approach that balances functionality and user comfort. In this work, validated through user feedback in a series of relevant repetitive tasks, we demonstrate that FleXo can reduce the perceived physical effort during lifting tasks, enhance user satisfaction, improve employee well-being, promote workplace safety, decrease injuries, and lower the costs (both to society and companies) associated with lower back pain and injury.