Design, fabrication, and testing of an ergonomic brace for virtual reality headset using 3D printing

Rapid adoption of virtual reality (VR) headsets introduced new ergonomic challenges, particularly neck strain caused by head-supported mass. This study presents a methodological framework for designing ergonomic interventions using 3D scanning, computer-aided design, and additive manufacturing. A VR ergonomic intervention-brace (VRB) was developed to redistribute headset load from neck to shoulders. Thirty-two participants performed office-simulated VR tasks under standard and VRB conditions. Neck muscle activity was assessed using surface electromyography, perceived discomfort using Borg's scale, and task performance using Fitts' law-based accuracy and reaction time. Results showed that the VRB significantly reduced cervical trapezius (-13%) and sternocleidomastoid (-12%) activation without affecting task performance. However, perceived neck discomfort increased with the VRB, likely due to mobility constraints. The methodology integrated anthropometric data and digital fabrication, enabling customised, low-cost ergonomic interventions. Findings highlight the potential of additive manufacturing for rapid, anthropometrically informed design of support systems addressing VR-related musculoskeletal risks.