Exoskeletons have come a long way from being something out of a sci-fi movie. Developed to augment human strength, endurance and mobility, exoskeleton technology is increasingly being used across industries to enhance worker productivity and safety.

Exoskeletons are robotic frameworks that work in conjunction with the human body to amplify its natural abilities. By transferring weight and providing power assistance at the joints, they help reduce physical strain and fatigue. Early exoskeleton prototypes were bulky and hardly mobile. But advances in materials, miniaturization and power systems are making new generation exoskeletons lighter, more dexterous and practical for real world applications.

Military and Emergency Use

Militaries have been at the forefront of exoskeleton development and use. Exoskeletons allow soldiers to carry heavy equipment over long distances with less fatigue. They also help reduce injuries from repeated or forced motions. Notable military exoskeleton projects include Ekso Bionics' EksoVest which unloads up to 20 kgs from the wearer's back and hips, and Lockheed Martin's Warrior Arm which augments lifting, pulling and carrying capacity.

Emergency response teams are also beginning to incorporate exoskeletons. The Japanese firm Panasonic has developed a search and rescue exoskeleton that can help firefighters stay active for longer periods during disaster relief operations. Its Power Loader CL-1 Model can carry over 30 kgs of payload weight and provide power assistance to the lower back and legs. Such exoskeletons could play a big role in disaster hit areas by boosting rescuer endurance and payload capacity.

Industrial and Manufacturing Sectors

Perhaps the biggest impact of exoskeletons will be felt in industrial settings where repetitive and strenuous manual tasks are common. Automotive, electronics and heavy manufacturing industries are actively experimenting with various upper and lower body exoskeleton models from Ekso Bionics, Sarcos, SuitX and others. Early adopters point to increased productivity, less absenteeism and lower workers' compensation insurance rates.

Tasks like overhead drilling, precise assembly and heavy lifting are well suited for exoskeleton assistance. Companies like Toyota, Ford and Airbus are using upper body exoskeletons to reduce physical stress on assembly line workers. Ekso Bionics' EksoVest and EksoZeroG for example help lift up to 18kgs of weight from workers' shoulders and back. Exoskeletons also open up possibilities of an aging workforce effectively participating for longer due to physical augmentation. However seamless integration into existing workflows remains an ongoing challenge.

Advancing Through Research

While several exoskeleton models are already commercially available, continuous R&D is expanding the scope and improving performance. Major technology players, startups as well as academic institutes worldwide are driving innovative exoskeleton designs and solutions. Additional funding from DARPA, EU and other organizations indicate the strategic industrial and military importance of this emerging field.

Improved Materials and Ergonomics

Lighter composite materials and 3D printed components are making exoskeletons more comfortable to wear. Adjustable designs and touch sensitive interfaces also allow for varied body sizes and natural coordination with wearer motions. This prevents interference or constraints during work. Flexible soft exosuits are another area of intense research as they conform more closely to the body without bulk or restrictions.

Power and Battery Breakthroughs

Reliability and duration of battery powered exoskeletons remain key challenges. Researchers are working on efficient transmission mechanisms, portable high density battery packs as well as alternative energy scavenging designs. German startup Anthropic's cable driven soft exosuits and Harvard's fluid powered soft exosuits are examples of diverse approaches to decrease battery dependency. Fuel cells and efficient power management will expand operational times beyond a few hours.

Sensor Fusion and Controls

To optimize assistance, exoskeletons need comprehensive sensing and feedback control. Integration of biomechanical models with data from onboard sensors like force plates, EMG sensors, motion trackers and more enables customizable power profiles matched to individual users and tasks. Learning algorithms also help scale assistance based on real time user exertion levels. Advanced controls will make exoskeletons smarter, safer and easier to use.

While exoskeleton technology has made tremendous progress, much remains to be done before it becomes mainstream. Addressing technical challenges around size, cost, precision and reliability is crucial to fully unlock its industrial and societal potential. Large scale deployments and long term health impact studies will also be important to identify best practices. However as power, materials and mechatronics continue advancing at a rapid pace, human augmentation through exoskeletons is poised to transform multiple fields in the coming years. It promises to make physically demanding jobs safer and more inclusive while also enhancing human physical capabilities for both civilians and defense forces alike.

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