Ergonomic Research Highlights Role of Exoskeletons in Preventing Work Related Injuries
New studies point to the importance of early intervention and biomechanical innovations in reducing long-term disability risks, especially among younger workers.
- By Messe Dusseldorf
- Jun 03, 2025
As musculoskeletal disorders (MSDs) continue to rank as the leading cause of work-related disability worldwide, researchers at the Fraunhofer Institute for Manufacturing Engineering and Automation IPA are intensifying efforts to address the problem through early prevention and technology integration — including the use of exoskeletons.
“Musculoskeletal disorders are no longer an issue limited to older workers,” said Dr. Urs Schneider, Director of Medical and Biomechanical Technology at Fraunhofer IPA. “Prolonged strain and physically demanding jobs are triggering complaints early in workers’ careers. That’s why it’s essential to implement ergonomic measures right from the start.”
With increasing life expectancy and a globally aging workforce, ergonomics experts stress that delaying prevention can result in lifelong impairments and costly workforce disruptions.
Ergonomics 101: The TOP Principle
Dr. Schneider advocates for the TOP principle, a hierarchical approach to workplace ergonomics:
- Technical solutions first, like lifting aids and workstation adjustments.
- Organizational changes next, such as task rotation.
- Personal protective strategies as a last resort.
He notes that while exoskeletons are gaining traction, they should not be the default solution. “They are valuable when standard ergonomic interventions fall short, but they’re not the first choice,” he said.
Advancing Exoskeleton Research and Evaluation
At Fraunhofer IPA’s Stuttgart facility, teams are conducting advanced biomechanical field and lab analyses, developing application-specific exoskeletons, and evaluating them using digital human models. Additional research includes mechanical testing for durability and safety to ensure real-world functionality.
A promising new research avenue focuses on the role of exoskeletons in secondary and tertiary prevention — particularly for people with disabilities. “We’re working with integration institutions in Germany to develop structured methodologies for choosing and deploying exoskeletons as assistive devices,” Schneider said.
What Is the EXOWORKATHLON®?
Fraunhofer IPA also leads the EXOWORKATHLON®, a prospective study simulating real-world conditions to test exoskeletons’ performance across various job tasks. Courses are co-designed with industry and healthcare experts, ensuring that findings remain practical and scalable.
Visitors to A+A 2025 — the international trade fair for safety, security, and health at work — will get a firsthand look at these developments. A highlight of the event will be the EXO PARK, a hands-on exhibition area organized in partnership with Messe Düsseldorf.
Attendees can try out exoskeletons, view the EXOWORKATHLON® live demonstration, and participate in the WearRAcon Europe conference, which brings together experts to discuss the latest in exoskeleton technology and ergonomic innovation.
A+A 2025 will take place from November 4–7, 2025, at the Düsseldorf fairgrounds.
Visit www.aplusa-online.com and www.mdna.com for more information on attending or exhibiting.
About the Author
Messe Düsseldorf is among the most successful trade show organizers worldwide. It hosts around 40 trade shows, including 20 leading international ones, at its 613,000-m² exhibition center in Düsseldorf, Germany. Across 18 halls, international market leaders and top decision-makers of various sectors get together every year in order to present and discover innovations, to exchange ideas and to network. Abroad, Messe Düsseldorf organizes more than 70 events. The corporate group’s global network encompasses 77 foreign representatives for 142 countries – including seven international subsidiaries.