SMART TECH & IoT
Embedding ergonomics into electronic design
Dr Jae Son I
While engineers are accustomed to optimising electronics for performance, effi ciency and form factor, one aspect can often be overlooked – how the product feels and fi ts. Here, Dr Jae Son, CEO and founder of tactile sensor specialist PPS, outlines the role of tactile sensing in helping to embed ergonomics into electronic design.
n embedded electronics, wearables and medical devices, human-device interaction matters as much as processing speed or battery life. Poor fi t can lead to device abandonment, non-compliance in medical settings, plus irritation and injury. Yet ergonomics is rarely quantifi able in early-stage design, leading to reliance on subjective feedback, or ‘trial and error.’ As electronics become more integrated into our routines, designers must optimise for how devices are worn and used, not just what they do. Human-centred design is becoming essential across many areas from consumer wearables, industrial tools, surgical equipment to AR/VR systems. These products interface to the body, so even small ergonomic issues can affect how comfortable they are to use, and whether people actually want to use them. In industrial environments especially, we know that poor ergonomics can contribute to higher rates of musculoskeletal strain, making thoughtful design even more important.
The role of tactile sensing Traditional fi t testing is a subjective process which is often infl uenced by human bias and user perception. Today, device design no longer has to rely on anecdotal evidence but can be driven by data. Pressure and force sensing data can be embedded into prototypes or testing rigs to measure contact forces in real time, while engineers can visualise how a device interacts with the body and can investigate pressure hotspots and gradients, fi t variabilities or any movement issues associated with the device. By using embedded capacitive sensors in testing or in-fi eld settings, developers can capture high-resolution data on how force is distributed across contact surfaces – such as a glove gripping a tool or a wearable headset resting against the skull. This allows design grounded in evidence rather than guesswork.
Deloitte’s 2021 Connectivity and Mobile Trends survey found that 39 per cent of wearable users stopped using a device because it was uncomfortable to wear, highlighting the importance of comfort and fi t for long-term use. With sensor-based testing, potential issues can be addressed earlier in the design process and improve user adoption.
Use cases
Headsets, augmented reality systems and sleep apnoea masks must balance fi rm contact with comfort and accommodate a wide range of skull sizes and shapes. Engineers can now use pressure sensing headforms in combination with embedded sensors to capture consistent data on pressure distribution. This enables comparisons across design iterations and helps reduce pressure peaks that could cause discomfort or slippage during use. With repeatable data, developers can create more inclusive designs that accommodate anatomical variation.
In industrial environments, poor tool ergonomics contributes signifi cantly to fatigue and musculoskeletal injury. Sensor- enabled gloves or test rigs allow designers to capture high-resolution data on how forces are distributed across the palm, fi ngers and wrist when a user interacts with a tool or interface.
This information is being used to redesign grips, reposition switches, or adapt materials to reduce high-strain zones. A 2016 study in Applied Ergonomics found that pressure mapping gloves could reliably identify injury risks in tool design, particularly in repetitive- use scenarios.
Sensor data also supports comfort evaluation in motion, under real-world conditions like temperature, moisture and user movement.
The calibration factor
For pressure and force sensing to be reliable, sensors must be calibrated to account for environmental variables, material interfaces and the specifi c geometries in which they’ll operate.
Application-specifi c calibration techniques, such as simulating hand grip or head contact using pressure bladders and jigs, help reduce variability and increase confi dence in test data. In safety-critical sectors like medical, aerospace and automotive electronics, this level of rigour is essential not only for usability but also for regulatory compliance. The ability to capture pressure and force data during real-world use is changing how developers think about ergonomics. Instead of relying on subjective fi t tests or user feedback alone, design teams can now work with concrete data from early-stage prototypes, enabling better decisions, faster iterations and ultimately, more inclusive and user-friendly products.
As sensor technologies evolve, ergonomic validation is likely to become a core part of electronic product development; especially in sectors where comfort and compliance are essential to long-term success. With over 25 years of experience in tactile sensing, PPS is helping to make comfort and fi t measurable in electronic design. To fi nd out more about PPS’s use of tactile and pressure sensors.
22 DECEMBER/JANUARY 2026 | ELECTRONICS FOR ENGINEERS
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42
