Applied Ergonomics, Biomechanics, Physics and Kinesiology


Belt: Building the ideal belt to make an orthotic connection to the human body started by looking at lumbar support belts for weight lifters; and then I looked at back support belts for movers. The one piece, continuous wrap belt, was selected over the legacy segmented belts to provide full contact and ideal support for the lumbar. Worn correctly, the top of the belt pad should ride above the top of the iliac crest.

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Spine Orthotic: The objective is to provide as much range of motion as possible, while still transferring any connected weight to the orthotic belt. The spine should be rigid enough to resist bowing under heavy load, but flexible enough for torsional twisting. Achieving the ideal performance meant testing different materials like corrugated sign plastic, ABS, kevlar, UHMW, carbon fiber, and now Tegris. Materials selection is a design tradeoff between function, cost, and workability. The grail that we are looking for would be fragment protection, combined with ABS flex, and UHMW cold weather resistance. In the meantime, ABS has provided the right mix; thin for lighter loads and ticker for heavier loads.

See ExoSpines

Spine Shape: The ideal shape took many iterations to achieve. A close fit, like an internal frame backpack put too much pressure on the lumbar with a rigid spine. A straight spine allowed ventilation, but pushed the weight too far away from the center of gravity. The hybrid between the 2 options keeps the weight close to your center of gravity, but still allows air movement between the rib stiffeners.

The entire concept of our ExoSpine harkens back to the use of pack-boards decades ago. Heavy, awkward, protruding tools were strapped onto a board that was fitted with shoulder straps and maybe a belt. The aha moment for me was when I was out dirt bike riding and my plastic chest protector got hung up on my kidney belt; the weight was off my shoulders and significantly more comfortable.

The width of the ExoSpine remains wide to achieve our goal of fragmentation protection with sufficient coverage. To prevent rolling, when worn over armor, the frame became concave at the top to match the shape of a ballistic plate. The concave section helps to prevent barreling when the pack is stuffed full, and additional air movement when worn without body armor.

 Additional Advantages: 

  • Lighter weight
  • Eliminate redundant parasitic weight
  • Optimum load distribution
  • Quick ditch
  • Easy don
  • Ergonomic fit
  • Quick customization
  • Unrestricted movement
/Users/alexklein/Desktop/PAK Folders/Ilya 2020/2020-05-20 - AttackPak/AttackPAK - Animation v1 - 30 seconds.mp4