In Episode 14 of the Exoskeletons and Wearable Robotics podcast, Dr. Tom Sugar and I have the pleasure of chatting with Sarah Ballini-Ross, an ergonomics solutions professional with practical experience working with small, large, and multinational corporations, as well as a small farm owner herself.

Sarah Ballini-Ross brings her unique expertise in navigating occupational exoskeletons from the perspective and needs of large organizations down to sole proprietorships. What makes industrial exoskeleton installations successful, and when is it time to seek help when piloting and implementing new ergonomic solutions?

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For more information regarding the material in this episode, please visit:
Evolving Innovation: https://innovatepnw.com
Listen to Sarah’s Podcast:    • Hard Hats & Heart – Leading with Human-Cen… 
Exoskeleton Report: http://exoskeletonreport.com
Wearable Robotics Association: https://wearablerobotics.com

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Episode Summary (AI-generated):

The conversation begins by framing the central question: how to make occupational exoskeletons practical for organizations of every size, from family-run shops to global manufacturers.  It stresses that exoskeletons should never be treated as stand‑alone gadgets; they need to sit inside a broader ergonomics and safety program that first exhausts simpler “hierarchy‑of‑controls” fixes.  Only when engineering changes, layout tweaks, and basic aids are maximized does an exoskeleton become the next logical step.

A recurring theme is the gap between buying an exoskeleton “out of the box” and rolling one out through a structured implementation.  Proper fit, user training, and precise task matching determine whether the device helps or merely overheats and frustrates workers. Short, hands‑on demo sessions can spark interest, but real success comes when employees are involved in selecting the model, adjusting it, and deciding which tasks truly justify wearing it.

Several field anecdotes illustrate both the promise and the pitfalls of this approach. In one case, a refrigeration technician tried a hip‑assist device during a full day of crouched work and immediately asked how to purchase it for his crew—a textbook win because the benefit was felt on the very first bend.  In another instance, kiln operators found a similar device unusable: extreme ambient heat, combined with additional safety layers, made the exoskeleton simply too hot to tolerate.  The lesson is that environmental constraints, not just biomechanical ones, can make or break adoption.

Cost and culture emerge as bigger hurdles for small and medium‑sized businesses than for large enterprises.  Smaller firms are nimble and can approve pilots quickly, yet they seldom have surplus safety budgets, dedicated ergonomists, or easy access to vendors.  Because regional trade shows and distributors rarely carry exoskeletons, these companies struggle even to try a device. The discussion argues that subsidies, grants, or innovative insurance programs could speed uptake in the mid‑market.  A handful of musculoskeletal disorder grants have already offset pilot costs, but broader incentives may be needed as hardware iterations arrive quickly and can outpace small-business purchasing cycles.

Beyond injury prevention, productivity gains, recruiting advantages, and perceived employer care are cited as powerful—but often overlooked—returns on investment.  Complementary technologies , such as wearable sensors, computer vision risk scoring, VR/AR training modules, and cobots, can be combined with exoskeletons to form a digital, human-centered safety ecosystem. They can provide that employee trust and engagement are addressed upfront.

Adoption barriers are particularly acute in agriculture and other mobile, piece-rate industries: migrant crews rotate among farms, margins are thin, and the equipment is expensive for individual workers to purchase.  Yet there are clear “quick‑win” niches—continuous ground‑level lifting, overhead welding, rebar tying, logistics picking, dental and surgical procedures, where the tasks are repetitive, the load predictable, and the workforce more stable.

The session closes with a call for better outreach: meet tradespeople where they already shop, embed devices in trade school curricula, and share everyday success stories rather than only large-enterprise case studies. Free consultations, short pilots, and industry‑specific messaging can turn what still feels like “mystical” technology into a standard tool on the jobsite.

Special thanks to Sarah for her time and first-hand knowledge. Visit Evolving Innovation and schedule a consultation to assist with your exoskeleton pilot and integration.