For warehouse and factory workers, even lifting light objects over and over can eventually take a painful toll. Repetitive strain injuries are among the most common workplace problems, accounting for nearly a third of all occupational injuries in the United States. Engineers at the University of Texas at Arlington think they may have found a way to lighten the load – literally.
Researchers at UTA have developed a soft robotic exoskeleton called the Pneumatically Actuated Soft Elbow Exoskeleton, or PASE. The device uses air-powered silicone actuators that flex naturally with the wearer’s movement to assist with lifting, drilling, and assembly tasks. It is designed to reduce muscle fatigue before injuries even begin, rather than simply supporting recovery after one.
Unlike bulky metal exosuits seen in sci-fi movies, PASE is lightweight, flexible, and surprisingly simple. It aligns perfectly with the user’s natural elbow motion, mounted on a carbon-fiber base wrapped in soft neoprene. The system connects to pneumatic lines already available in most factories, making it a plug-and-play option for workplaces that want to reduce strain without overhauling their setups.
The UTA team, led by professors Mahmudur Rahman and Muthu Wijesundara with research scientist Veysel Erel, tested the design on 19 participants between the ages of 18 and 45. Each participant performed common industrial tasks such as manual lifting, basic assembly, and power drilling. When the exoskeleton was engaged, researchers recorded up to a 22 percent reduction in bicep and tricep activity. Participants also reported feeling noticeably less physical and mental strain, scoring up to ten points lower on NASA’s Task Load Index.
The device doesn’t just take the edge off fatigue – it could save companies money and workers from long-term injury. Musculoskeletal injuries cost American businesses up to 54 billion dollars each year in healthcare expenses and lost productivity. Reducing strain before it becomes an injury could mean fewer workers sidelined and more consistent productivity across industries.
Dr. Erel, who leads UTA’s soft robotics program, said the real goal is prevention. “Even delaying or preventing a single workplace injury makes a huge impact,” he explained. “Projects like this show how engineering can directly improve people’s quality of life by reducing fatigue and creating safer work environments.”
Following the success of the initial study, the UTA team has proposed expanding the concept into a full upper-limb system that would assist not only the elbow but also the wrist and fingers.
The study, published in the Journal of Rehabilitation and Assistive Technologies Engineering, points to a future where soft robotics quietly handle the hardest part of physical labor, letting human workers save their strength – and their joints – for another day.
