From idea to finished product: The development story of the B900 active back exoskeleton

From idea to finished product: The development story of the B900 active back exoskeleton

Musculoskeletal disorders (MSDs) are among the most common causes of absenteeism in industry. The back is particularly at risk. At exoIQ, we knew that we wanted to develop exoskeletons that put people first. Following the success of our active shoulder exoskeleton S700, the next logical step was to develop a system for the area that bears the greatest strain—the lower back. And so began the journey to the active back exoskeleton B900.

The origin of the idea: Why your back needs relief

People who are physically active on a daily basis often first notice the strain in their lower back. Initially, this manifests itself only in minor tension or occasional pain. However, if these symptoms are ignored, they can lead to serious long-term health problems, including musculoskeletal disorders. In Germany, these are among the most common reasons for sick leave. The consequences are far-reaching: permanent complaints, in the worst case premature retirement from work, and considerable financial burdens for employers and the healthcare system.

Our goal is to use exoskeletons as the right tool to provide relief where workers face the greatest risks. With shoulder and back support, we cover 90% of the relevant needs in industry and trade.

From concept to prototype: The biggest challenge

Exoskeletons are not machines that replace humans. They are tools that empower and relieve humans. When developing the B900 active back exoskeleton, one key question therefore arose:

How can we achieve maximum relief while maintaining full freedom of movement?

Dr. Andreas Argubi-Wollesen, biomechanics and movement scientist at exoIQ, describes the biggest challenge as follows:

"How can we develop an exoskeleton that provides noticeable support when moving heavy loads while maintaining human mobility?"

A patented mechanism was developed for the product to achieve full freedom of movement. Ergonomic adaptability was also a key focus of the development process.

Focus on ergonomics: Adaptation to every body type

Richard Kosub from the Product Development and Patent Management department at exoIQ explains:

"A major issue in development is always the question of how the exoskeleton can be adapted to different people. Where do we need adjustments, where do we need joints to ensure that the user can move without restriction?"

During the development process for the B900 active back exoskeleton, the focus was on adaptability, among other things—for example, the back length can be adjusted to suit both short and tall body sizes. The result is a product that not only works technically, but also feels like a natural part of the body.

The first design prototype: a major milestone

The moment when all the design considerations of the last two years become tangible for the first time is particularly impressive and groundbreaking. Björn Hipp, responsible for technical design and user experience at exoIQ, describes the design prototype phase as follows:

"It's incredibly exciting to see all the pieces come together for the first time. The design now really looks like an exoIQ product and expresses exactly what we want."

Details were optimized with each prototype—right down to the finest details. The result: an exoskeleton that not only impresses technically, but also sets new standards in terms of ergonomics and aesthetics.

The finished product: relief, comfort, and design

After around two years of development, we now have a new product that sets new standards: the B900 active back exoskeleton noticeably relieves strain on the back, offers full freedom of movement, is extremely comfortable to wear—and looks really good too. You can wear your exoskeleton with pride.

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