ExoBak
Lightweight Back Support for Physically Demanding Work
ExoBak is a lightweight, passive back-support exosuit developed to assist workers during repetitive bending and lifting tasks. Designed with affordability, comfort, and practicality in mind, it offers an alternative to bulky, expensive exoskeleton systems without relying on motors, batteries, or electronics.
The Challenge
As automation continues to transform logistics and manufacturing, much of the physically demanding work still depends on people.
We initially focused on delivery drivers, whose jobs involve repeated lifting, bending, and carrying throughout the day. Our research revealed an opportunity to make wearable back support more accessible without compromising the freedom of movement workers need.
The goal was to develop a solution that was lightweight, affordable, comfortable to wear, and practical enough for everyday use.
The Solution
ExoBak uses a semi-flexible back structure and interchangeable elastic bands connected to the thighs. As the wearer bends forward, the bands stretch and store energy, which is released to provide assistance when returning to an upright position.
The back structure also provides tactile feedback to encourage more controlled lifting posture. Adjustable straps and interchangeable elastics allow the level of support to be adapted to different users and tasks.
The result is a passive wearable system designed to work alongside the body's natural movements.
Design, Prototype, Repeat
ExoBak evolved through three major design generations and more than 100 prototypes and iterations.
Throughout development, we explored different materials, elastic configurations, fastening mechanisms, and manufacturing methods. Each iteration helped improve the device's fit, comfort, functionality, and ease of use.
Physical prototypes were evaluated in workplace settings, including a three-week pilot involving five workers. Feedback from these trials helped identify practical improvements and understand how the device performed beyond controlled demonstrations.
Beyond the Prototype
The project was showcased at industry events, including the Detroit Auto Show, and received several recognitions:
2022: Wearable Robotics Association Innovation Challenge — Fan Favorite Award
2022: University of Houston Battle of Classes — First Place
2023: City of Houston Liftoff Business Plan Competition — First Place, $10,000 award
ExoBak was developed through ExoBraced, an independent startup co-founded by Misfit founder Mehdi Mortazavi. The experience shaped our approach to product development today: design for real people, prototype early, learn from testing, and consider manufacturability from the beginning.