Spring-Powered Exosuit to Prevent Low Back Pain due to Overuse Injury

Abstract: Low back pain is a leading cause of disability worldwide and is a frequent cause of missed work, costing billions of dollars per year in medical expenses and lost productivity. Much of this pain is due to overuse injuries, which result from repetitive musculoskeletal forces that cause microdamage to accumulate faster than tissues can heal. Healthcare workers are at high risk of back overuse injuries due to frequent bending and lifting: For nurses and operating room staff, there is a 50-70% annual and 80-95% lifetime prevalence of back pain/injury. Back pain and injury fuel the opioid crisis and can be career-ending, but there are currently no solutions available that are practical, effective, affordable and acceptable to most healthcare workers. Exoskeletons (including soft exosuits) are an emerging technology that shows promise in reducing overuse injury risks in industrial applications. This includes the HeroWear Apex exosuit, which was commercialized in 2020 and is now used in rt100 worksites in rt10 countries. This 3-lb. exosuit has been proven to reduce back muscle forces by 15-40% (without motors or batteries), and the assistance that it provides can be turned on/off as needed. Multiple studies confirm that healthcare workers are highly interested in exoskeletons that relieve physical strain. However, during its development efforts HeroWear has learned that the majority of healthcare workers need the capabilities of an exosuit in a device that 1) fits comfortably under medical scrubs (for safety and aesthetic reasons), and 2) assists in their most common back-straining tasks (bending 10-30°). The successful Phase I feasibility work resulted in 1) an under-clothing switch, 2) a robust on/off mechanism (i.e., clutch), and 3) confirmation that the Phase I device does not restrict movement. The primary remaining research and development challenges for Phase II are prompted by the fact that all commercial exoskeletons are outerwear (or middle-wear - e.g., worn over a shirt but under a safety vest), and that most are rigid and bulky. Recent research publications and HeroWear interviews confirm that the visibility of exoskeletons over clothing is the main reason healthcare workers do not use them. To address this key unmet need for healthcare workers who are at risk for back pain/injury, HeroWear is seeking SBIR Phase II support to continue developing a novel endosuit designed to 1) be worn comfortably under medical scrubs, 2) support mild bending postures, and 3) provide the same mode-switching (on/off) function that has been key to adoption of industrial exosuits, in order to meet the specific needs of healthcare workers. Phase II work will be focused on final prototype design, fabrication, and real-world validation studies. Phase II results will provide the key data needed to engage Phase III participation by private-sector investors, partners, and customers- enabling commercialization of endosuit technology that will greatly improve the health and well-being of millions of healthcare workers.