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

FleXo: A Flexible Passive Exoskeleton Optimized for Reducing Lower Back Strain in Manual Handling Tasks | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Article FleXo: A Flexible Passive Exoskeleton Optimized for Reducing Lower Back Strain in Manual Handling Tasks Federico Allione, Maria Lazzaroni, Antonios Emmanouil Gkikakis, and 3 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-6014305/v1 This work is licensed under a CC BY 4.0 License Status: Under Review Version 1 posted You are reading this latest preprint version Abstract 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. Physical sciences/Engineering/Biomedical engineering Scientific community and society/Business and industry/Engineering/Biomedical engineering Full Text Additional Declarations There is NO Competing Interest. Supplementary Files AllioneFleXoNatComVideo00.mp4 Lifting techniques and movements using FleXo Cite Share Download PDF Status: Under Review Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-6014305","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Article","associatedPublications":[],"authors":[{"id":416810674,"identity":"f1cabe58-4d75-4e34-8234-cd9ed8c33b50","order_by":0,"name":"Federico Allione","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAA7klEQVRIiWNgGAWjYBAC9gYGAwYQYmBgbjyQAKT4mRkboCLYAc8BuBbGBrAWyWbGRqA5uPVAtDBAtYAogwMM+K3hYW/e+LiiwE6Ogf1gw4EHFXfkjI8ztz9gKPiDWwvPsWLDMwbJxgw8iUCHnXlmbHaYgMPsJXLMJBsMDiQ2MAC1JLYdTtxGSAuP/Bvzn2At/A/BWuo3E/S+BI8ZI1iLBMSWBANmQlp40oqBDks2ZpN4CPLLYcMZQIfNSDAwxq2F/fDGjw1/7OT4+ZMPPvxRcViev//4gw8f/sjh1AIHbCi8BMIaRsEoGAWjYBTgAQAVnVbFg4C6HAAAAABJRU5ErkJggg==","orcid":"https://orcid.org/0000-0002-5282-2888","institution":"Istituto italiano di tecnologia","correspondingAuthor":true,"prefix":"","firstName":"Federico","middleName":"","lastName":"Allione","suffix":""},{"id":416810675,"identity":"32d2f50d-ab0b-4dc9-a6a8-d020d7f3b548","order_by":1,"name":"Maria Lazzaroni","email":"","orcid":"","institution":"Istituto italiano di tecnologia","correspondingAuthor":false,"prefix":"","firstName":"Maria","middleName":"","lastName":"Lazzaroni","suffix":""},{"id":416810676,"identity":"c5418a32-c55c-40d7-a19d-421abc534ec8","order_by":2,"name":"Antonios Emmanouil Gkikakis","email":"","orcid":"","institution":"Istituto italiano di tecnologia","correspondingAuthor":false,"prefix":"","firstName":"Antonios","middleName":"Emmanouil","lastName":"Gkikakis","suffix":""},{"id":416810677,"identity":"8211a0cd-4757-4d06-b3b3-b307a6b24848","order_by":3,"name":"Luigi Monica","email":"","orcid":"","institution":"Department of Technological Innovation and Safety Equipment, Products and Anthropic Settlements, Italian Workers’ Compensation Authority (INAIL)","correspondingAuthor":false,"prefix":"","firstName":"Luigi","middleName":"","lastName":"Monica","suffix":""},{"id":416810678,"identity":"4498afb7-7ea8-40d3-a073-c001e5c15ff2","order_by":4,"name":"Darwin G. 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