Can robotic exosuits improve soldier endurance and reduce injury risk?

How much can exosuits actually boost endurance?

The evidence shows substantial gains. In a 2024 case series, 88% of participants lifted more heavy objects while wearing an elastic back exosuit, with individual endurance increases ranging from 28% to 75% [2]. That means a soldier who could normally lift 100 boxes before fatigue might lift 128 to 175 boxes with the suit. For running, a lightweight passive exosuit (just 609 grams) reduced the energy cost of running by an average of 4.7% in seven out of eight participants [7]. While 4.7% may sound small, over a long march or patrol it translates to meaningful savings in metabolic energy, delaying exhaustion.

For tasks requiring sustained arm elevation, an active shoulder exosuit (Myoshirt) allowed participants to keep their arms raised 78.7% longer [4]. This is directly relevant to soldiers who must hold weapons or equipment overhead. The endurance gains are not just theoretical—they have been measured in realistic military field training exercises, where soldiers reported that exosuits increased their ability to perform duties [3].

Do exosuits really cut injury risk, or do they just let you work harder and get hurt anyway?

The key concern is that if an exosuit lets you lift more, you might simply do more work and accumulate the same or greater injury risk. But the data show this does not happen. In the same 2024 study where participants lifted 28–75% more, their cumulative back damage—a measure of low back disorder risk—was 27–93% lower when wearing the exosuit [2]. The suit offloads the spine so effectively that even doing many more lifts, the total strain on the back is still far less than without the suit.

This protective effect is backed by biomechanical design. The Bilateral Back Extensor Exosuit (BBEX), inspired by human spine anatomy, provides multidimensional force assistance during both symmetric and asymmetric lifting, and was shown to reduce muscle fatigue in the erector spinae muscles and mechanical loading on spinal joints [8]. In a military commanders course, a simple 5-minute injury prevention exercise program (not an exosuit, but targeting similar mechanisms) cut injury prevalence from 34.3% to 14.8% [1]. Exosuits take this further by providing continuous, on-demand mechanical support.

For soldiers, the implications are clear: exosuits can simultaneously boost productivity and lower injury risk, a rare combination. A 2024 review of socio-ethical aspects also notes that exosuits improve physical performance and reduce injury risk, though it cautions that implementation must consider psychological impacts and accountability [9].

Are exosuits practical for real military operations?

Field tests suggest they are. In a 2023 study, U.S. Army artillery soldiers wore a back exosuit during a realistic field training exercise. Feedback was overwhelmingly positive: approximately 90% reported that the exosuit increased their ability to perform duties, and 100% said they would wear it if further developed and made available [3]. The suit did not interfere with other tasks, which is critical for combat roles.

Weight and bulk have been historical barriers, but newer designs address this. A 2021 lightweight hip-flexion exosuit, described as the lightest powered exoskeleton at the time, reduced metabolic rate by 11.52% and muscle fatigue by 10.7–40.5% in key leg muscles [6]. A passive running exosuit weighs only 609 grams and protrudes just 2.5 cm from the body [7]. A lower-body exosuit with a single actuator (shared between both ankles) further reduces mass and cost while still reducing muscle effort [5]. These advances make exosuits far more wearable for extended missions.

However, challenges remain. A 2024 review highlights socio-ethical concerns, including potential impacts on soldiers' sense of autonomy and the need for clear accountability frameworks [9]. Also, most studies are short-term; long-term durability and battery life (for active suits) in harsh environments are not yet fully proven. But the trajectory is clear: exosuits are moving from lab curiosities to field-ready tools.

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