Researchers at Vanderbilt University have created a lightweight wearable device that can take up to 90 percent of the weight of body armor off a soldier’s shoulders and back.
This innovation could help reduce pain, prevent injuries, and make long missions more comfortable and manageable.
Their findings were recently published in the journal Applied Ergonomics.
The study was led by Paul Slaughter, a recent Ph.D. graduate, and Karl Zelik, an associate professor of mechanical engineering.
Together with senior research engineer Chad Ice, the team has also filed a patent for this new device.
According to Zelik, the goal is to support soldiers who often suffer from musculoskeletal injuries caused by carrying heavy gear.
He believes the device could help troops stay effective in the field and even speed up recovery from back injuries. The researchers are eager to collaborate with military programs interested in testing or improving the device.
This work builds on the team’s earlier success developing exosuits for the military.
Between 2021 and 2022, Zelik’s lab worked closely with soldiers from the 101st Airborne Division to create a wearable lift-assist suit designed to reduce injuries during heavy lifting and physically demanding tasks.
That earlier device became the basis for the commercial Apex 2 exosuit, produced by Vanderbilt spin-off company HeroWear, which now supports thousands of workers in the U.S. and internationally. The new device focuses on a different need: reducing the strain of body armor during everyday movement.
Body armor can be extremely heavy, and wearing it for long hours places a major burden on the back and shoulders.
The new device helps by redirecting much of this weight from the upper body to the hips, which are naturally better at bearing loads.
Tests with U.S. military veterans showed that shifting even a portion of the armor’s weight made standing and walking more comfortable, and redirecting up to 90 percent provided significant relief without affecting posture or muscle activity.
Slaughter said he is excited about the device’s potential to reduce strain while still letting service members move freely and perform all their duties.
The design includes several thoughtful features that make it practical for real-world use. It has retractable load-bearing elements that engage when needed but stay out of the way at other times.
The prototype weighs just 2 pounds, works without batteries or motors, includes quick-release functions for emergency situations, and allows full agility and freedom of movement. These features were developed through a user-focused design process, with input from soldiers and Army experts.
Back overuse injuries are among the most common problems in the U.S. Army, affecting nearly one in five active-duty soldiers each year. Wearing armor for long periods can significantly increase the risk of low back pain—a problem also seen in police officers.
Zelik, recently recognized as a Master Innovator by Vanderbilt, hopes this device will not only reduce injuries but eventually make a meaningful impact across both military and civilian communities.
