Creating safe and effective work environments doesn’t necessarily begin and end with good engineering. It involves understanding human behavior in real-world settings. That’s where motion capture data steps in, revolutionising ergonomic workplace design by aligning it with actual human movement. Combining the insights of human factors engineering and human factors psychology with motion capture data transforms the design process into one driven by precision and evidence. The result? Workspaces and products that promote well-being, reduce risk, and enhance performance.
What is Ergonomic Design and Why It Matters
Ergonomic design involves comfort, but more importantly is about functionality, safety, and long-term health. By tailoring tools and environments to natural human capabilities and limitations, we minimise strain and enhance focus. Poorly designed workspaces, by contrast, contribute to fatigue, errors, and injuries. Studies show that even small postural issues can lead to chronic musculoskeletal disorders, driving up healthcare costs and reducing productivity.
Engineers have long used ergonomic assessment tools like RULA, REBA, NIOSH lifting guidelines, SNOOK tables, and anthropometric datasets to measure and improve design quality. These quantitative and qualitative tools are still valuable, but they often miss subtle biomechanical trends. They also depend heavily on the observer’s interpretation, which can lead to inconsistent results.
As our interaction with digital tools and machinery grows more complex, ergonomic workplace design becomes ever more critical. In 2025 and beyond, we need methods that can keep pace with evolving work environments. That’s where motion capture data and ergonomic analysis software come in.
The Role of Human Factors Engineering and Psychology in Design
Human factors engineering (HFE) seeks to optimise systems by designing for the human user. It incorporates psychological principles such as perception, attention, stress response, and motivation into the engineering process. Human factors psychology focuses on how people interact with technology and physical environments, identifying where those interactions may go wrong and how to mitigate risk.
Rather than designing products based solely on mechanical properties or theoretical performance, human factors engineering in design ensures that users can interact with systems comfortably, intuitively, and safely. This shift from machine-centric to human-centric design results in smarter workstations, better tools, and more effective workflows.
With motion capture technology, engineers now have the opportunity to embed human factors engineering considerations from the earliest design phases. The result is not only improved usability but also measurable gains in safety and efficiency.
Limitations of Traditional Ergonomic Tools
Traditional ergonomic assessment methods, including paper-based checklists and 2D video analysis, have limitations. These observation-based techniques are labor-intensive and often fail to capture the full picture, especially in fast-paced or complex environments. They can’t accurately quantify joint angle velocity, cumulative loading, or muscular fatigue.
In addition, traditional methods offer limited insight into variations across populations. An assessment that works for an average-sized adult may not account for differences in stature, mobility, or strength. This lack of inclusivity is a growing concern for modern engineering teams focused on equitable and universal design.
In the Handbook of Human Factors and Ergonomics Methods, author Neville Anthony Stanton states: “There is no one best way or one best tool for conducting ergonomics analyses. Selection of an appropriate technique or tool will depend on the specific application, environment, criticality, required accuracy, learning curve, and cost justification.”
Motion capture offers a remedy by collecting high-resolution, objective data that eliminates guesswork and highlights ergonomic issues with unmatched clarity.
How Engineers Use Motion Capture for Ergonomic Design
Motion capture data gives engineers a precise view of how people move through their work. Vicon’s cutting-edge optical and inertial systems record movements at up to 2,000 frames per second. By tagging key body points with reflective markers or using markerless setups, engineers can capture a wide range of motions in real-world conditions.
Key benefits include:
- Quantitative tracking of posture and joint angles during different tasks
- Mapping of natural reach envelopes to optimize placement of controls or tools
- Measurement of grip dynamics to inform handle design and reduce wrist strain
- Simulation of interactions for people of different sizes, abilities, or who are wearing protective gear
These motion capture datasets integrate directly with ergonomic risk assessment tools and ergonomic assessment software. This means engineers can apply validated models, such as RULA, REBA, and NIOSH, within digital platforms to generate actionable data fast.
Motion Capture as an Ergonomic Assessment Tool
Vicon’s systems are not just about recording movement, they form the backbone of ergonomic analysis software that enables evidence-based decision-making.
- Real-Time Feedback: In environments like line balancing workshops, mocap data allows operators to see immediate results. For example, a digital avatar might turn red when lumbar flexion exceeds a safe threshold, prompting instant correction.
- Recorded Analysis: For deeper assessments, recorded sessions allow analysts to replay footage, zoom in on specific moments, and overlay motion paths. Joint angle curves can be exported into multibody dynamics or finite-element models for further stress and fatigue testing.
- CAD and Digital Human Model Integration: Motion capture data is fully compatible with leading platforms such as Siemens Jack and Dassault DELMIA. Designers can use ergonomic software solutions to test alternative configurations before manufacturing even begins.
Reducing Strain and Improving User Comfort
With motion capture data, engineers gain a precise, real-time understanding of how individuals perform routine and critical tasks in real-world settings. This visibility is crucial for reducing physical strain and enhancing user comfort across a variety of roles and environments.
- Identifying Inefficient or Risky Movements in Workflows: Motion capture systems allow ergonomic analysts to pinpoint movements that fall outside of safe biomechanical ranges. For example, repetitive lumbar flexion, shoulder overreach, or wrist extension can be flagged and addressed. This data-driven approach eliminates guesswork and ensures that the riskiest parts of a task are not overlooked during observation.
- Designing for Varied Populations (Height, Mobility, Strength): Not all workers have the same stature, flexibility, or strength. By capturing data from individuals across a wide demographic range, engineers can simulate and test environments for inclusivity. This includes designing adjustable workstations, optimal tool heights, and adaptive equipment that supports workers with different physical characteristics or limitations, such as PPE constraints or reduced mobility.
- Using Mocap Data to Validate Design Improvements: One of the most powerful aspects of motion capture technology is its ability to quantify improvement. Engineers can capture baseline data, implement a design change, and then re-capture to see measurable improvements in joint angles, postural alignment, or task duration. Whether it’s a handle redesign that lowers ulnar deviation or a platform height adjustment that improves spinal alignment, mocap provides concrete evidence of progress.
Case studies underline the practical value:
- At Embry-Riddle Aeronautical University, engineers used Vicon systems to assess pilot entry into a cockpit. The analysis showed excessive shoulder abduction, leading to a 32% reduction in torque after panel repositioning.
- Timken deployed markerless mocap to optimise deburring tasks. Adjustments led to a reduced risk score and a nine-second gain per cycle.
- NASA integrated mocap with VR to evaluate technician movements during spacecraft maintenance, using real-time visual alerts to prevent risky reaches.
Putting it into Practice: Best Practices for Ergonomic Motion Capture
To extract maximum value from motion capture and ergonomic risk assessment tools:
- Start with a Clear Goal – Identify whether you’re addressing safety, speed, inclusivity, or long-term health outcomes.
- Capture Comprehensive Tasks – Include entire workflows, not just the high-frequency steps. Don’t forget edge cases like tool changes or maintenance tasks.
- Apply Validated Scoring Models – Use ergonomic assessment software to convert motion into meaningful risk scores using tools like REBA or RULA.
- Refine and Re-Test – Even small changes in handle diameter or screen height can yield large ergonomic improvements. A second motion capture session helps confirm gains.
How Mocap Enhances Ergonomic Assessment
As the demands on workers and designers grow, so too must our tools. Motion capture data transforms ergonomic assessment from a subjective art into a measurable science, grounded in human factors engineering and human factors psychology. Engineers can now design tools and environments that genuinely fit the people who use them, reducing risk and increasing productivity.
For teams seeking to create smarter, safer, more inclusive designs, Vicon’s motion capture systems and ergonomic software solutions offer a future-proof path forward – explore Vicon’s Human Factors Engineering solutions today.