Design and Development of Wearable Exoskeleton Systems for Industrial and Healthcare Applications

Abstract

Wearable exoskeleton systems are revolutionizing both industrial and healthcare sectors by enhancing strength, supporting rehabilitation, and reducing musculoskeletal strain. This paper examines design principles, development methodologies, and application-specific considerations for wearable exoskeletons, drawing on pre-2019 case studies and pioneering systems. Key industrial examples include DARPA’s BLEEX (Berkeley Lower Extremity Exoskeleton) and Ekso Bionics devices, which assist in load carriage and ease fatigue in labor-intensive tasks. In healthcare, systems like HAL (Hybrid Assistive Limb) and ReWalk have enabled paraplegic patients to walk, while upper-limb rehabilitation platforms such as CLEVERarm demonstrate modular, ergonomic, and multi-DOF joint designs. The paper synthesizes literature on comfort-optimized mechanics (e.g., rolling knee joints, backdrivable actuation), biomechanical control (torque compensation for minimizing joint stress), and passive assistive wearables (e.g., Archelis wearable chair). A consolidated design methodology is proposed—from need assessment through ergonomics, actuation, control architecture, and field validation. Findings show that successful exoskeletons balance mechanical efficiency, comfort, and intuitive control; industrial exosystems emphasize payload support, while healthcare systems prioritize alignment and user autonomy. Advantages include reduced injury risk, enhanced mobility, and quality of life; challenges entail weight, bulk, cost, battery limitations, and regulatory hurdles. The conclusion highlights the necessity of multidisciplinary integration—mechanical design, control engineering, ergonomics, and user-centered validation—for exoskeleton success. Future work should focus on lighter materials, improved human– machine interfaces, compliant and soft designs, longer battery life, and rigorous safety evaluation.