What is a leg exoskeleton and how does it work?
Before considering an investment, it is essential to understand what we are talking about. An exoskeleton is not simply a piece of protective equipment: it is a wearable device that literally assists the body in its movements. For an SME, this technology opens up concrete opportunities in terms of risk prevention and performance.
Definition and basic principles
An exoskeleton is a mechanical or motorised structure that is worn on the body. It follows the user's morphology and supports, guides or amplifies natural movements. Unlike a robot that would replace the human, the exoskeleton works with them.
The leg exoskeleton specifically targets the lower limbs: knees, hips, ankles. It is particularly relevant for prolonged squatting postures, repeated lifting or carrying loads. The principle is simple: reduce the mechanical strain on joints and muscles.
Its operation relies on three pillars:
- Sensors that detect movement intentions (joint angles, pressure, muscle signals).
- Actuators or passive systems (springs, counterweights) that provide assistance.
- A mechanical structure that supports posture and transfers forces to more robust areas of the body.
The different types of exoskeletons
Not all exoskeletons are equal, and the choice depends directly on the intended use. There are generally four main categories:
- Passive exoskeleton: it uses springs, elastic bands or counterweights to relieve the joints. No external energy is required. This is the simplest, lightest and often least expensive solution.
- Active exoskeleton: motorised, it actively assists movement through actuators. It can be programmed and adapted to specific tasks, but requires a power source (battery).
- Rehabilitation exoskeleton: designed for recovery after an injury, surgery or stroke. It is used in medical or paramedical settings.
- Professional exoskeleton: designed for the world of work. It meets requirements for robustness, safety and prolonged wear. This is the category that directly interests SMEs.
In the context of an SME exoskeleton, the professional model is almost always the right choice. It is designed to be worn for several hours a day, withstands demanding environments (dust, humidity, temperatures) and integrates with existing personal protective equipment.
How does it work in practice?
The principle may seem abstract. Here is what happens, in practice, when you put on a leg exoskeleton:
- Detection: sensors analyse in real time the position of your body segments, the pressure exerted and sometimes the electrical activity of your muscles (EMG).
- Synchronised assistance: the system provides motor torque (or a return force) at the right moment, that is, when your body needs it most.
- Reduced effort: muscular effort decreases, fatigue sets in later, posture improves naturally.
The result is immediate and measurable: less tension on the knees and lower back, better endurance throughout the day, and a feeling of lightness in repetitive movements.
Why do SMEs have everything to gain by adopting an exoskeleton?
Large companies have already started equipping themselves. But it is often SMEs that suffer most severely from the consequences of musculoskeletal disorders, for lack of suitable prevention resources. Adopting an exoskeleton is no longer a luxury reserved for large groups.
Reduction of musculoskeletal disorders (MSDs)
MSDs are the leading cause of occupational disease in France. They massively affect the construction, logistics, agri-food and healthcare sectors. For an SME, each case of MSD results in sick leave, emergency replacements, loss of skills and sometimes a declaration of unfitness.
A leg exoskeleton directly reduces the load supported by the knees, hips and lower back. By reducing joint strain, it limits wear and delays the onset of lesions. Fewer MSDs means fewer sick leaves and fewer situations where the company loses an experienced employee.
Lower absenteeism and improved productivity
An equipped employee feels less fatigue at the end of the day. They maintain a more stable work pace, reduce their micro-breaks and no longer need recovery days. Some studies show productivity gains of up to 20% in physically demanding roles.
For an SME, these gains are far from anecdotal. A team that keeps up the pace without exhausting itself means better quality of service, deadlines met and reduced pressure on managers.
Improved workplace health and company image
Investing in an exoskeleton sends a strong signal: the employer genuinely cares about Quality of Working Life (QWL). In sectors facing labour shortages, this is a differentiating argument for attracting and retaining candidates. An SME that offers a work environment preserving physical health immediately stands out.
Add to this direct savings: fewer workplace accidents, fewer compensation payments, fewer increased contributions.
What return on investment (ROI) for an SME?
This is often the first question managers ask. The good news: the ROI of an exoskeleton in an SME is generally quick, provided the calculation is properly structured.
Acquisition cost and financial aid
The price of a professional exoskeleton ranges from €3,000 to €15,000 depending on the technology, level of assistance and features. This amount may seem high, but it is largely offset by existing subsidy schemes: AGEFIPH, Regions, OPCO, CARSAT and other prevention organisations.
Exyvex offers solutions adapted to SMEs and supports you through the funding process. In many cases, the subsidy covers between 30% and 50% of the investment.
ROI calculation: a simple method
To assess profitability, simply follow a four-step logic:
- Estimate the annual cost of MSDs in your organisation: sick leave, replacements, lost productivity, compensation.
- Compare with the initial investment minus the subsidies obtained.
- Add the indirect gains: reduced absenteeism, increased productivity, lower turnover.
- Calculate the time needed to break even.
In the majority of cases, ROI is achieved within 12 to 24 months.
Worked example for an SME with 50 employees
Let's take a concrete case to illustrate the logic:
| Item | Amount |
|---|---|
| Average cost of an MSD per year per employee (INRS source) | €2,500 |
| Employees affected (10% of 50) | 5 employees |
| Annual cost of MSDs | €12,500 |
| Purchase of 5 exoskeletons at €5,000 | €25,000 |
| Subsidy (50%) | - €12,500 |
| Net investment | €12,500 |
| Estimated annual saving (MSDs + productivity) | €12,500 and more |
In this scenario, the investment is recouped in less than a year, without even counting productivity gains and reduced turnover.
How to choose the best exoskeleton for your SME?
The market is developing rapidly, and not all models are equal. To avoid an unsuitable purchase, you need to structure your approach.
Analyse the specific needs of your activity
Three questions to ask yourself above all:
- Sector: construction, logistics, industry, healthcare, agri-food? The constraints are not the same.
- Tasks: carrying loads, prolonged squatting, repetitive movements? The exoskeleton must target the main strain.
- Environment: confined spaces, extreme temperatures, wearing PPE? The model must be able to adapt to them.
Technical and ergonomic criteria
Beyond price, several criteria should guide your choice:
- Weight and bulk: an exoskeleton that is too heavy will be abandoned.
- Battery life (for active models): it must cover a full working day.
- Ease of adjustment: it must adapt to different morphologies without complex tools.
- Comfort and acceptability: this is the number one factor in adoption by teams.
Hiking vs professional exoskeleton: don't confuse them
Beware of confusion. A hiking exoskeleton is designed for endurance and leisure: it helps you walk longer on a trail. It is neither robust, nor secure, nor suitable for intensive professional use.
A professional exoskeleton meets safety standards, withstands daily use and forms part of a risk prevention approach. Exyvex offers models specifically designed for work environments.
Test before buying
Never choose an exoskeleton from a catalogue. Ask for on-site trials with the operators concerned. Involve the teams in the decision: it is the best way to encourage adoption. Also check the availability of after-sales service and training.
Aid and subsidies for purchasing an exoskeleton in an SME
Financing an exoskeleton in an SME is more accessible than one might think. Several schemes exist, often combinable.
Main sources of funding
- AGEFIPH: for the employment and retention of disabled workers.
- CARSAT / CRAMIF: as part of occupational risk prevention.
- OPCO: funding for training and sometimes equipment.
- Regions and departments: aid for innovation and modernisation.
- France Relance: schemes for the digitalisation and robotisation of SMEs.
How to put together a subsidy application?
- Carry out a risk assessment and a prevention plan.
- Choose an exoskeleton that precisely meets the identified needs.
- Prepare the application with quotes, a supporting case and ROI calculation.
- Get support from an experienced supplier.
Exyvex can support you throughout this process, from the initial analysis to preparing the application.
Implementation and employee training: the key stages
Preparation phase
- Raise team awareness of the benefits and limitations of the exoskeleton.
- Appoint an internal coordinator to lead the project.
- Schedule trial sessions and gather feedback.
Training in use
- Learn how to adjust the exoskeleton to your morphology.
- Understand the assistance modes and their limitations.
- Know how to react in the event of a malfunction.
Monitoring and adjustments
- Regularly assess comfort and effectiveness.
- Adapt the settings to tasks and operators.
- Measure the gains: productivity, absenteeism, MSDs.
Testimonials and use cases in SMEs
In logistics
An SME with 30 employees equipped its order pickers. Within six months, sick leave for lower back pain fell by 40% and productivity increased by 15%.
In construction
A masonry company tested a leg exoskeleton for squatting tasks. Workers report less fatigue at the end of the day, and the staff turnover rate has decreased.
In the healthcare sector
A care home equipped its nursing assistants for patient transfers. The result: fewer MSDs and a noticeable improvement in quality of working life. Exyvex supported the implementation and training.
Conclusion: take action with Exyvex
Summary of benefits
- Employee health preserved and MSDs reduced.
- Improved productivity and quality of service.
- Fast ROI thanks to savings made and subsidies.
Next steps for your SME
- Carry out an assessment of your high-risk roles.
- Contact Exyvex for a personalised demonstration.
