Building the Real Iron Man _ Popular Science

Building the Real Iron Man

By Gregory Mone Posted 04.09.2008 at 11:11 am

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TAGSScience, Feature, darpa, exoskeleton,exoskeletons, Gregory Mone, hollywoodscience, may 2008, military, Raytheon, raytheon

While audiences flood theaters this month to see the comic-book-inspired Iron Man, a real-life mad genius toils in a secret mountain lab tomake the mechanical superhuman more than just a fantasy with the XOS Exoskeleton

Man Meets Machine Exoskeleton test pilot Rex Jameson greets XOS maker Steve Jacobsen John B. Carnett

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Afghanistan. A hidden bunker. Four men with rifles guard a thick, rusted steel door. Bam! A huge fist pounds against itfrom inside. Bam! More blows dent the steel. The hingesstrain. The guards cower, inching backward. Whatever's trying to break out is big. And angry.

The door flies open, and a metallic giant bursts through. It looks like a robot but, hidden inside, famed weapons designer Tony Stark maneuvers the mechanical beast. Bullets bounceoff the suit, barely denting his armor. He levels the guards with one swat. Outside, he stares down the enemy camp around him, switches on the flamethrowers in his arms, and roaststhe joint.

Utah. A secret mountain lab. Software engineer Rex Jameson backs into a headless metal suit that's hanging from a steel I-beam by a thick rubber cord. He clicks into the aluminumboots, tightens belts across his legs and waist, and slides his arms through backpack-like straps, gripping handles where hands would be. It looks as easy as slipping into an overcoat.

Then he moves, and the machine comes to life, shadowing his every motion. He raises his fists and starts firing sharp jabs while bouncing from one foot to the other. He's not quiteMuhammad Ali, but he's wearing 150 pounds and he looks light.

He could easily knock a nearby coder to the floor, or fling one over a deskbut even more impressive, he could do it all day. To showoff his superhuman endurance, he walks over to a weight rack and yanks down a bar loaded with 200 pounds. Then he does it again.And again. He stops somewhere around 50, but he's been known to rip through 500 reps in a row. Even then, he quits out of boredom,not fatigue.

It's fantasy versus reality, and the spread is shrinking. The latter, the XOS, is the latest and arguably most advanced exoskeleton inexistence, developed by one-man idea factory Steve Jacobsen and the engineers at Sarcos, a robotics company he started in 1983 thatwas recently purchased by the defense giant Raytheon. The flame-throwing monster? That's the star of the superhero blockbuster IronMan, due out May 2. The film follows a prolific inventor named Tony Stark who builds a robotic suit of armor that grants him fantasticalabilities. Iron Man has been thriving in comics for more than four decades, but this is Hollywood's first go at the story. And the timingcouldn't be better. Not only is Iron Mana hero born of pure engineeringthe perfect idol for our gadget-obsessed era, but for the firsttime since the character appeared, the suit is more than just an illustrated dream.

In the past seven years, a handful of engineers have taken the military's 40-year-old fantasy of mechanically enhanced soldiers that cancarry heavy loads and begun to make it real. Funded with millions from the Pentagon's Defense Advanced Research Projects Agency(Darpa), Jacobsen and others have finally begun marrying artificial muscles and control systems into suits that could soon be availableto soldiers, firemen and the wheelchair-bound. There are still serious challengespowering these wearable robots, for onebut

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sarcos xos, robotics, robots, sarcosSarcos's XOS, the most capable full-body suit, one that moves seamlessly with its wearer, has even the comic's creators feeling like thereal world is catching up to their vision. After Adi Granov, one of the main illustrators of the comic and a consultant to the film, watched aclip of the suit in action, he was startled. "I knew that's where we were heading, but I didn't realize we were this close," Granov says. Aside from the lack of flight and weapons, headds, "that's Iron Man."

Check out video of the XOS in action here, and for a brief photo history of the man-made exoskeleton, see our gallery here. Continue reading this feature below.

From Marvel to Machine

If you want to untangle the technological roots of the fantasy against which any real exoskeleton will be compared, you need to visit the place where the comic evolved: the MidtownManhattan headquarters of Marvel, Inc. There, Tom Brevoort, the editor who oversees the Iron Man comics, gives me a short biographical summary of Tony Stark: MIT grad, superstarscientist and engineer, heir to a fortune, womanizing alcoholic. The story of how he becomes Iron Man has changed over the years, but the basic idea, and the one the movie hasadopted, is that some bad guys take him hostage and demand that he build them a killer weapon. He constructs a suit of armor instead and, after escaping, resolves to improve boththe suit and himself, transforming from an immature brainiac into a true superhero.

Look, One Hand: Because a wearer of the XOS feels almost no strain, he could hold these 16-pound bowling balls for hours on end John B. Carnett

Iron Man can outrace a jet, dead-lift 1,000 tons, hack into high-security computers, and do it all through a direct brain interface. Far-fetched? Sure, but Brevoort says that's the point."Iron Man's always got to be three steps ahead of the best things you've got, or he's a fossil."

When the character appeared in 1963, the best the military had was a concept on paper. That year, U.S. Army researcher Serge Zaroodny published a report describing his design fora wearable robot that would endow the operator with Hulk-like power, but the necessary technology didn't exist to make it viable. Besides a few non-military designs [see timelinephoto gallery here], the prospect of an actual super-suit languished until 2000, when Darpa began a seven-year, $75-million program called Exoskeletons for Human PerformanceAugmentation. By that time, a handful of exoskeleton championssuch as former Army colonel Jack Obusek, the director of human systems integration at the Natick SoldierResearch, Development and Engineering Center in Natick, Massachusettsbelieved that the technology had begun to catch up. Obusek, who has helped push for the military'sexoskeleton research since 1995, says the rise of smaller, more versatile sensors and faster microprocessors began to convince him and other officials that a wearable robot just mightbe buildable.

But Darpa's ambitious wish list read like something from a comic: a machine that would let the average soldier lug hundreds of pounds and hike for days without fatigue, handleweapons that normally require two people, and whisk the injured off the battlefield by tossing one or two men on his back. They asked for the suit to support more armor, renderingmen impervious to enemy fire. They even wanted it to make soldiers jump higher. They wanted Iron Man.

Some of the experts Darpa consulted before launching the program didn't agree that this vision was realistic. "Half the people I talked to believed, almost as if it was a religious thing,and about half thought it was a complete waste of money, time and resources," says Cornell University engineer Ephrahim Garcia, who led the Darpa program in its infancy. Thenaysayers were hardly crazy, he adds: "It was a huge challenge." The exoskeleton would need a portable power system that could keep it running for up to a full day; small, powerfulartificial muscles; and a complex control system that governed their actions. And it would need to be fast.

The exoskeleton would have to be the soldier's mechanical shadow, reading his every motionthe left arm is swinging in this direction with this much forceand mimicking him almostinstantly. Even the slightest lag would create a drag-like effect and make the operator feel as if he were moving through water. The machine would also need some way of readingforces applied across the suit thousands of times per second, plus microprocessors powerful enough to turn all that data into immediate directions for the robot's limbs, so they couldkeep pace with the person inside.

Solving these problems, and figuring out how to combine the systems into a machine with the requisite speed, agility, strength and endurance, called for a real-world Tony Stark. Butthat turned out not to be a hotshot weapons designer. It was a guy who was building robot dinosaurs.


Meet the Robot Maker

Steve Jacobsen's rsum makes him seem like the Willy Wonka of roboticshis projects over the past 35 years have spanned an 80-ton mechanized dinosaur and the Bellagiocasino's fountains. But he looks more professor than madman, tall with a board-straight back and perfectly groomed gray-white hair. Before introducing the XOS, he leads me on a tourof what he only half-jokingly calls his "tunnel of terror." It could pass for a dentist's office from the outside, but the cavernous space is the headquarters of the company he founded asan R&D arm of the University of Utah's college of engineering, where he taught at the time. Although he's built robots for some notoriously tough customershe hints that Disney isjust as demanding as the militaryhe's still an academic at heart. He refers to his brain as a friend he likes to go off and spend time with, and he seems to care more about solvinghard problems than about the solution's ultimate application. After skipping right past a Ping-Pong-playing humanoid 'bot, he lingers in front of a pair of singing, mechanical toucans hebuilt for a local restaurant, marveling at how difficult it was to make them move like real birds. "We just do things we want to do because they're interesting," he says.

He talks in five-minute-long bursts on topics that range from expressions of wonder at the energy efficiency of biological systems ("Humans run on carrots!") to reflections onengineering to starry-eyed platitudes ("Some things have to be believed to be seen"). But his chattiness belies a penchant for secrecy. He rarely talks to the press. He won't tell me hisage. As we walk though various labs, he'll point to a devicea miniature unmanned ground vehicle, a new design for an exoskeleton leglaunch into an excited explantion, and thenstop and ask me not to mention it. His reticence stems in part from the fact that several of his projects are military-funded. But there's also a hint of the magician who's not keen toreveal too many of his tricks.

The mix of Sarcos's projects, which also include prosthetics and nanoscale motors, seems random. But Ephrahim Garcia says this versatility is part of what made Jacobsen uniquely


2 of 16 09.07.2013 16:36

Beyond: Raytheon Sarcos XOS: The mostadvanced real-world exoskeleton yet, theXOS, grants its wearer extraordinarystrength and endurance. To read more aboutthe development of the XOS, read ourfeature article here. John B. Carnett

Rear View: The box on the suit's backcarries the computer and control systems. John B. Carnett

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suited to the exoskeleton challenge. He had proven skills in software and mechanical engineering, but he also had the unique ability tosimply invent what he needed. "He can design the actuators. He can design the control system. He can design the machine and itscomponents," Garcia says. That kind of range was absolutely required.

How to Lift 200 Pounds Like It Was 2: The XOS works similar to a human appendage. When we perform a bicep curl, the muscle fibers in our upper arm contract, pulling on tendons that lift ourforearm. In the XOS, a sensor in the handle detects a force as the operator moves his arm. The sensors data goes to the computer, which calculates how to move the exoskeleton to minimize thestrain on the users hand. These instructions go to a series of valves that control the flow of high-pressure hydraulic fluid to cylinder actuators in the joints. The fluid moves the cylinders, whichmove the cables attached to them, acting as tendons and pulling on the robotic limbs. The XOS has 30 actuators, each controlling a different joint. Kevin Hand

"When you build something like an exoskeleton," Jacobsen says, "there are about 25 subsystems, and they all have to work before you can go on to the next step. The two mainobjectives are strength and endurance, but it's got to do 75 different things well." Of all his robots, the XOS, because of the host of problems it presented, is clearly his favorite son."None of them had a target like this. None of them had to have a self-contained system that has such strength, speed, endurance, flexibility."


An Exoskeleton is Born

In 2000, Sarcos applied for a piece of the Darpa money, in part because Jacobsen believed he had a solution for one of the biggest questions laid out in the original call for proposals:how the operator would interface with the robot. To confirm his hunch, Jacobsen asked the company's staff photographer, Jon Price, if his daughter would help with a little experiment.

The test called for Price to be, in effect, the exoskeleton, and his daughter to be the pilot. With her back to her father, she stepped up onhis feet, her toes atop his. Then they held hands for balance and she began to walk. Price's job was to stay in step, to keep his feet dir-ectly beneath hers. Within a few minutes, they were moving in sync. His daughter made all the high-level decisionshow fast to walk,when to turnand Price just tried to mimic her, step for step.

The demonstration proved for Jacobsen that, given a few points of contactthe feet and hands, in this casea smart machine couldinterpret the intended movements of the person strapped into it and react accordingly. On the way to the finished XOS, Jacobsen and hisgroup designed compact actuators, built improved force sensors, invented more-efficient hydraulic valves, and even machined the robot'saluminum feet. But what Jacobsen calls his "get out of the way" control scheme is the big idea that brings it all together, the approach thattransformed it from just another of his cool robots into a superhero suit. Obusek, who has personally tried the XOS, agrees. "A human willfatigue fairly quickly even with very little resistance," he says, but the XOS's control system reduces that drag to nothing.

It's that control that enables demo pilot Jameson to cruise through a workout without raising his heart rate. The instant he starts to pulldown that weighted bar, sensors in each of his hand-grips register changes in torque. Without the exoskeleton's help, the sensors wouldshow that he was trying to pull down about 100 pounds in each hand. But the goal of the system, Jacobsen explains, is to get the force onthose sensors as close to zero as possible; to let the XOS do the work. "The XOS carries itself," he says, "and [Jameson] carries himself."

Those hand-grip sensors, along with similar ones in the suit's feet and back, feed measurements to a central processor hundreds and, forsome of the sensors, several thousand times per second. The system runs these readings through a set of equations that governs theposition and motion of the suit's arms, legs and back. It recognizes that Jameson wants to bring his hands down and calculates what eachartificial muscle in each of the joints needs to do to make the suit mirror him. Jameson never feels strain because the system instructs therobotic arms to grab the weight before he exerts any significant force. When he steps out of the XOS after a round on the weight machine,he's not even out of breath. I ask him how he feels. "Fine," he says, shrugging.

The suit Jameson has been using is roughly version 4.0. Jacobsen shows me a room where the first three models hang like mannequins. It reminds me so much of Iron Man's "Hall ofArmor," where Stark keeps his suits, that I'm tempted to check the crime blotter in the area, see if there have been any instances of vigilante justice by a half-man, half-robot.

The first suit, built in 2002, didn't even have power. The Sarcos team constructed it to prove that the exoskeleton would be able to move like we do. Jacobsen had one of the engineersstrap in and try things like kicking a soccer ball, running, climbing into the tight cab of a bulldozer. This helped them determine that they had the right range of motion and the joints inthe right places.

Getting those joints to open and close with the proper speed and power proved trickier. In 2003, Sarcos began working on hydraulicallydriven actuators to function as mechanical muscles. This approach isn't revolutionary. In fact, says another exoskeleton builder, thesuit's reliance on hydraulics will be its downfall. One engineer, who declined to be named because he hadn't seen the suit in person (its


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Video: The XOS Exoskeleton inAction

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TAGSScience, Feature, darpa, exoskeleton,

exoskeletons, Gregory Mone, hollywoodscience, may 2008, military, Raytheon, raytheonsarcos xos, robotics, robots, sarcos

Pant Suit: Berkeley Bionicss ExoHikerlower-body exoskeleton charges itselfthrough the act of walking using regenerativeforce, much like a hybrid car does. CourtesyBerkeley Bionics Team

only public display is in a video shot by a local TV news crew that got uploaded to YouTube), said that a purely hydraulic system wouldwaste too much power maintaining fluid pressure in the valves. Electric actuators could be better, he suggested, because the energythey use would be proportional to the action. But Jacobsen testily dismisses this critique. "Do you like the brakes on your car? Do youlike the landing gear on a plane to work? Those are both hydraulic," he says. Then he explains that he's gotten around the energy-drawproblem. Although he's characteristically cagey about the details, he says Sarcos redesigned the valves that control the flow of the fluidto be more of an on-demand system, so they consume power only when the suit moves.

Despite its prowess in the weight room, the XOS hasn't hit all the goals of the Darpa program. It won't let you dunk a basketball or runany faster, and it won't turn you into a Hercules. But one of the objectives of Darpa's rigorous list of demands, Obusek says, was simplyto see whether any of them would be possible. Of the three teams that took part in the project (Sarcos, Oak Ridge National Laboratory,and the University of California at Berkeley), the XOS emerged in 2005 as the suit closest to the agency's initial vision. As a result, it isthe only full exoskeleton the military has moved into the next development stage; Sarcos is now working under a two-year, $10-millionArmy grant.

Jameson steps back in for a final, relaxing workout, and as I watch this 150-pound robot mirroring his every move by way of just sixpoints of contact, and consider the amount of data flowing around the suit every second to keep those actuators moving quietly andseamlessly, the whole scene seems as fantastic as the movie's Iron Man. I half expect Jameson to blast off through the roof. But that'snot going to happen. For the XOS to bust out of this cave, they're going to have to cut the power cord.


The Other Power Players

The world of exoskeleton researchers is small, secretive and a little catty. Even when they aren't sure exactly how someone else's suitoperates, the builders aren't afraid of lobbing keep-this-between-you-and-me digs at each other. The most common is some form of "Askhim how he's going to power it." The XOS and the two other leading exoskeletons in the U.S. have approached this critical question fromopposite angles. Jacobsen decided to make an extremely capable suit first and figure out later how to power it for 4 to 24 hours, as Darpamandated. During all the demos I watched, Jameson and the suit were tethered to a hydraulic pump that draws electricity from an externalpower supply. (The suit can operate from batteries, but only for 40 minutes at a time.) But the country's other two top exoskeletondesigners, Massachusetts Institute of Technology professor Hugh Herr and Homayoon Kazerooni of the University of California atBerkeley, began with the power problem.

Herr is trying to build a leg-powering machine that uses as little energy as possiblethe first iteration draws a mere two watts, comparableto a portable radiobut can support 80 percent of an 80-pound load on a user's back. In its current design, because of the way it affectshis gait, the wearer burns slightly more energy with the suit than if he were just walking with the load alone. But Herr thinks that within thenear future, he can improve the mechanics so that the machine actually saves the wearer effort. Ultimately, he envisions weekendwarriors using exoskeletons as recreational tools, strapping in so they can run through the mountains all day. While Herr muses aboutthese kinds of self-powered systems as a long-term dream, Kazerooni implies to me that he's already part of the way there.

Kazerooni, another veteran of the Darpa program (neither he nor Herr has so far gotten additional money from the military beyond theoriginal grant), says his Human Load Carrier (HULC) lower-body exoskeleton can operate for more than 20 hours without recharging. Hesays it allows the user to carry 100 pounds on his back and burn 15 percent less oxygen than if he was supporting the added weightalone.

Kazerooni's device wasn't ready for a public unveiling and, when pressed for details, would say only that the system is analogous to thatof a hybrid car. Just as a hybrid uses the energy transferred during braking to recharge its battery, HULC capitalizes on the forcetransferred from the ground each time the user plants his weight on a different leg. The very act of walking keeps it juiced. He's now in themiddle of a three-year, $2-million grant from the National Institute of Standards and Technology to modify his system so it can help peoplewith mobility disorders. "This isn't just a war machine," he says. "Our machine could replace the wheelchair."

The closest competitor to the XOS is also a medical device, but on the other side of the Pacific, in Japan. Roboticist Yoshiyuki Sankailaunched a company in 2004 called Cyberdyne (the same name as the firm that sparks the robot revolution in the Terminator films,incidentally) to market his full-body exoskeleton, now known as the Hybrid Assistive Limb, or HAL-5. Rather than using force sensors likethe XOS, sensors in HAL-5 attached to the wearer's skin pick up signals from his muscles to determine how he wants to move. The suit'scontrol system studies and then mimics a person's natural gait. This means it takes up to half an hour for the suit and the operator to getin syncyou can't just snap in and go. But since Cyberdyne sees the HAL-5 as both a rehabilitation device and nurse's assistant, thetraining period may not matter. Strapped into the battery-powered suit, a hospital worker could hoist heavy patients as if they were kids.Sankai is leasing the suit to customers now.

Check out video of the XOS in action here, and for a brief photo history of the man-made exoskeleton, see our gallery here.Continue reading this feature below.

Breaking Free

In a recent Iron Man comic, the hero is lying beaten on the floor of his enemy's lair, and the head-up display in his armored helmet feeds him the bad newshe's almost out of power.But there's still hope. He jams a finger through the concrete floor into a power line and quickly recharges his suit.

Unfortunately, real-world exoskeletons take more than a stolen jolt to power up, so the first XOS in the field may even be tethered. Obusek envisions this early version to be more of aworkhorse than a warrior. A plugged-in suit, borrowing energy from a vehicle or a ship's generator, could help a soldier rapidly unload a helicopter stacked with heavy equipment orrepair tanks with broken tracks. Although the Army hopes to begin field-testing this version of the XOS by 2009, Jacobsen and company are still working toward an entirelyself-powered version.

This summer, the company will launch a research program with an engine-design firm to develop a generator capable of powering the XOS for hours at a time. Jacobsen won't tell meany more than that, but not just because he's being coy. He'd rather talk about a more interesting challenge than building a robust power supply: cutting the suit's appetite.


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What a Kick: Sarcoss senior electrical engineer, Todd Johnson, demonstrates a next-gen leg, which can swing freely, just like a real leg does, so it uses less power. John B. Carnett

Jacobsen shows me a new, energy-saving leg that's modeled on human propulsion. When we walk, we generate most of the power from the hip when we push off. Then, as the legswings forward, the small muscles in our knees and elsewhere rest before making sure our feet hit the ground at the desired spot. That free-swinging technique saves energy.Kazerooni and Herr have already incorporated it into their legged exoskeletons, and Jacobsen is building it into the future version of his XOS. "The next step," he says, looking ahead afew years, "is to get the power down to the point where we can walk using about one to three horsepower"little enough to run on a portable power pack.

Jacobsen sees today's version as a base vehicle that will eventually be modified to fit specific tasks, whether in health care, emergency response, maintenance or war. Future modelscould even operate autonomously. "You could get out and tell it, 'Why don't you go in that building, because I don't want to,'" he says.

Later, walking through the Raytheon Sarcos lobby, I spot a few animated incarnations of this long-range vision rolling on a flat-screen TV. In the clips, armored soldiers throw heavymissiles on their shoulders, hurdle high walls, speed through combat rolls, even execute graceful backflips. Though encased in an XOS, they look as nimble as NFL cornerbacks. Theylook like Iron Man.

Contributing editor Gregory Mone has been reading Iron Man comics since he was 10 years old.

Check out video of the XOS in action here, and for a brief photo history of the man-made exoskeleton, see our gallery here.

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Shin 04/09/08 at 4:26 pmsexy.

Link to this comment

The Adama 04/09/08 at 5:49 pmI'd rather have a HAL-5. Do an image search for it, it's pretty awesome.And it's been around for years.


Ewok 04/09/08 at 11:00 pm=O wowJust out of curiosity, if you were lifting weights in the suit, would that buildyour muscle? If so, it could help people in rehabilitations to lift like a



5 of 16 09.07.2013 16:36

bajillion pounds and gain there muscle back, or help me show off to theladies :)

wakeskater_X 04/10/08 at 1:56 amEwok:

It wouldnt matter if you could lift a million pounds in the suit, you gainmuscle on how much YOU lift. So if the suit makes lifting a million poundsequivalent to lifting 10 pounds... you might as well just lift a 10 poundweight because its the same.

^_^


Bluelaser 04/10/08 at 4:33 pmHmm thats pretty cool. I can see why the military is paying out-the wazoofor this thing. Personaly i think it should be used for construction, to saveon energy and only have to endanger 3 men instead of 50.

Also i dont like the idea of wasting it fighting battles, it seems like kind of awaste if u ask me.

And the disabled thing is a really great idea if you can make it lessnoticeable, and or bulky.

-Word.of.Warcraft


mwesty64 04/11/08 at 6:42 pmI like the idea of an exo suit, but using hydrualics to move the limbs seemsoutdated for something so advanced. when will they come up with sometype of synthetic muscle that minipulates the human muscle better adnfaster.


Starwalker 04/12/08 at 5:13 amI think idea is good and maybe not a perfect but still it is abeginning /in progress I mean/.Maybe when that apparatus have more good connection withhuman body and they work in symbiosis...


TimeToThink 04/12/08 at 6:51 amThe technology is facinating, though I fear that we are moving far to slowlywith advancements in science. It is taking far to long to come up with newadvancements. There are not enough people that are of literal geniusstatus or near genius status involving themselves in science. Myself, I amashamed that I don't even know how to type or spell properly, even thoughI was seen as a pheonom as a child. Remember Einstein was bad withphone numbers. I need to educate myself. I fear it is coming far to late inmy life, but I have to try. I spent to much time drinking beer, and not enoughtime diving into books. I will say this for the exo-skeleton, it is worth waitingfor. The applications are going to be quite varried. I just don't want to see acollege kid hitting a bong off campus meeting his death to the new rookie ofthe patrol squad as he rolls up and torches the poor chitlin... Ow!

CAN YOU SAY POLICE BRUTALITY?


McMevan 04/12/08 at 9:00 pmHey mwesty64, I dont see how hydraulics are outdated. That would be likesaying I dont see why they use wheels for cars, they should hover by now.An application such as this uses quite advanced technology to syncappropriately with the movement of the body and could be used for anumber of different things other than supplementing a human engaged incombat....


lschlesi 04/12/08 at 10:01 pmThis is an old idea in the science fiction world going back to the 40s, 50sand 60s. If you are going to do a power suit timeline, how about mentioningRobert Heinlein's flying (or at least high-jumping) combat power suits in hisoriginal Starship Troopers novel (1959) or the power suit in the Robocop(1989) movies.

Anytime a human and a machine integrate in an intimate way to performtasks that a human being could not perform on his or her own, (SteveAuston, The Six Million Dollar Man-1973 anyone?) you essentially have acyborg, even if the connection is only temporary. It doesn't matter if themachine is enhancing human muscles/sensors or replacing them.

Of course the suits will eventually be used in other than military roles. Itscall spin-off and it has been going on since military technology started toadvance from stone knives and bear skin shields. Most likely the firstLink to this comment


6 of 16 09.07.2013 16:36

civilian application for the military type of power suit will be heavyconstruction.

However, this is not an either or situation. This technology can be appliedto both civilian and military uses without taking away from either one. But Iguess its pretty easy to talk about the use of such power suits to defendthe United States and give our troops the best protection and firepower asa waste when your sitting safe, sound and free here in the states whilesomeone else is doing the heavy lifting to defend you overseas, isnt it?

It should be mentioned that power "waldo" (again, from Robert Heinlein inhis 1942 short story of the same name) style mechanical "hands" arealready being used for dangerous remote work and medical applications.Such manipulators can scale up or down (for delicate work like micro-surgery) the movements and apparent strength of the operators hands andarms. They have been used for years in the medical, chemical and nuclearindustries.

One suggestion... No armor is truly impervious against the right kind ofcounter weapons. Even heavily armored tanks can be destroyed orpenetrated with certain types of shoulder launched rockets and even highcaliber rifle fire. So, there will be casualties, even amongst soldiers wearingheavily armored power suits. It might be a good idea to program theelectronics in the power suit to automatically run, walk or even crawl (if themachine can still move at all) the wounded or dead combat soldier back tohis own lines, once the on-board computer determines by monitoring thephysical condition of the operator that the soldier in incapacitated.

This way, a wounded trooper could get medical attention as soon aspossible or, at least, the body could be recovered. It would also keep theformidable weapon that the suit represents from falling into enemy hands.Biometric lock-out systems could also be used to prevent an enemy fromacquiring a usable power suit.

This might be a good idea for the current crop of military tanks andarmored vehicles in cases where the machine can still function, but theoccupants are out of action. The robot vehicle driving systems that havewon the DARPA trials could point the way to such automated recoverysystems.

Tromba Prima 04/13/08 at 12:38 amAs mentioned above in a previous comment, you have made a seriousomission in your article, "Building the Real Iron Man." You forgot to mentionthat master science fiction author Robert A. Heinlein envisioned poweredarmor suits back in 1959 in his superb novel Starship Troopers (not to beconfused with the 1997 film that turned out to be a travesty by the samename allegedly based upon the book).

A suit isnt a space suitalthough it can serve as one. It is not primarilyarmoralthough the Knights of the Round Table were not armored as wellas we are. It isnt a tankbut a single M.I. private could take on a squadronof those things and knock them off unassisted if anyone was silly enough toput tanks against M.I. A suit is not a ship but it can fly, a littleon the otherhand neither spaceships nor atmosphere craft can fight against a man in asuit except by saturation bombing of the area he is in (like burning down ahouse to get one flea!). Contrariwise, we can do many things that noshipair, submersible, or spacecan do.

And it may even be possible that Heinlein was not the first one to come upwith the idea.

So, let us give credit where credit is due.


Tromba Prima 04/13/08 at 12:40 amAs mentioned above in a previous comment, you have made a seriousomission in your article, "Building the Real Iron Man." You forgot to mentionthat master science fiction author Robert A. Heinlein envisioned poweredarmor suits back in 1959 in his superb novel Starship Troopers (not to beconfused with the 1997 film that turned out to be a travesty by the samename allegedly based upon the book).

A suit isnt a space suitalthough it can serve as one. It is not primarilyarmoralthough the Knights of the Round Table were not armored as wellas we are. It isnt a tankbut a single M.I. private could take on a squadronof those things and knock them off unassisted if anyone was silly enough toput tanks against M.I. A suit is not a ship but it can fly, a littleon the otherhand neither spaceships nor atmosphere craft can fight against a man in asuit except by saturation bombing of the area he is in (like burning down ahouse to get one flea!). Contrariwise, we can do many things that noshipair, submersible, or spacecan do.

And it may even be possible that Heinlein was not the first one to come upwith the idea.

So, let us give credit where credit is due.


Starlord 04/13/08 at 12:34 pm Link to this comment


7 of 16 09.07.2013 16:36

If you research back to around 1960, Mechanix Illustrated had an articleabout a suit of armor the Army was supposed ot be experimenting with.Their article was much more complete than this one. The suit of armorcould completely seal the soldier off from the atmosphere, in the even ofbiological or radiation dangers. They could parachute and cut loose fromthe canopy 30 feet from the ground and land, They could brace themselveson a berm and act as a launching pad for a missile. They carriedsupersized grenades they could throw 3/4 of a mile or drop at their feet.Some time later, a scifi writer brought out a series of books about a secretgroup of soldiers who conducted SEAL-type missions using suits of armorthe same as described in the MI article. Later, on, the series was expandedto a group of Russian soldiers in Russia's version of the suits. It seemsPopSci was scooped by MI and a scifi writer.

"In it's most basic form the right to keep and bear arms is nothing less thanthe right to maintain the means of one's own self-defense. If a manchooses not to arm himself, that is his choice and right. It is NOT his rightto force HIS choice upon ME."

BluestreakWRX 04/15/08 at 10:30 amThis project is something I've been aware of for the better part of a decade,it's called Halo. Heard of it? Neither have the writers or editors. This pieceof extraordinary hardware was ripped from Heinlein's books, copied looselyby James Cameron in Aliens, and brought to "life" by Bungie.

The writers and editors compared everything about the XOS to IronMan,when this is everything the SPARTANS (and to lesser extent ODST) arebased on. The XOS has as much in common with Iron Man as a talkingGPS has with Cortana.


ptdoyle 04/15/08 at 2:14 pmHeinlein did not invent the concept but he was the first to truly popularize itand relaize its potential. Thus making it unacceptable to leave him out ofany article on the subject


Floyster 04/16/08 at 2:02 pmThe picture in the actual Popsci magazine of what the suit might look like ina few years seemed extremely familiar. I found it similar to an earlyprototype of the Master Chief's armor as it appears in the game Halo:Combat Evolved for Xbox. The day when normal soldiers have Spartancombat suits might not be as far away as we think.


Jables 04/17/08 at 9:41 pmSeriously, if they put "Matrix Revolutions" on the exo suit timeline, why notput the SPARTAN armor from Halo? Also, the envisioned design of thefuture exo suit looks eerily like spartan armor, the helmet looks virtuallyidentical to Master Chiefs.


sivcool5 04/20/08 at 11:02 amThis is an old idea in the science fiction world going back to the 40s, 50sand 60s. If you are going to do a power suit timeline, how about mentioningRobert Heinlein's flying (or at least high-jumping) combat power suits in hisoriginal Starship Troopers novel (1959) or the power suit in the Robocop(1989) movies.


Of course the suits will eventually be used in other than military roles. Itscall spin-off and it has been going on since military technology started toadvance from stone knives and bear skin shields. Most likely the firstcivilian application for the military type of power suit will be heavyconstruction.


It should be mentioned that power "waldo" (again, from Robert Heinlein inhis 1942 short story of the same name) style mechanical "hands" arealready being used for dangerous remote work and medical applications.Such manipulators can scale up or down (for delicate work like micro-surgery) the movements and apparent strength of the operators hands andarms. They have been used for years in the medical, chemical and nuclearindustries. Link to this comment


8 of 16 09.07.2013 16:36




sivcool5 04/20/08 at 11:04 amThis is an old idea in the science fiction world going back to the 40s, 50sand 60s. If you are going to do a power suit timeline, how about mentioningRobert Heinlein's flying (or at least high-jumping) combat power suits in hisoriginal Starship Troopers novel (1959) or the power suit in the Robocop(1989) movies.


Of course the suits will eventually be used in other than military roles. Itscall spin-off and it has been going on since military technology started toadvance from stone knives and bear skin shields. Most likely the firstcivilian application for the military type of power suit will be heavyconstruction.


It should be mentioned that power "waldo" (again, from Robert Heinlein inhis 1942 short story of the same name) style mechanical "hands" arealready being used for dangerous remote work and medical applications.Such manipulators can scale up or down (for delicate work like micro-surgery) the movements and apparent strength of the operators hands andarms. They have been used for years in the medical, chemical and nuclearindustries.





new_reader 04/20/08 at 6:39 pmI think that the exoskeleton looks more like something from the game Halo.It looks like a spartan a.k.a. Master Chief then Iron Man.


jeremiahalexander 05/06/08 at 9:06 pmJacobsen is just starting to scratch the surface people. give him a littlecredit for trying something like this. he has the right ideas he just needs toimprove on them. Link to this comment


9 of 16 09.07.2013 16:36

just like any invention thats created. it just take time to perfect the workinparts so that they work beautifly. yes the H- 5 suit is better so far but theyhave been researching this for many years. i for one won't mind being apart of steve jacobsens project. i see great things happening in the next5-10 years. maybe even sooner.

1) my belief is that anything is possible in life. if you can imagin it, you havealready takin the first step in making it a reality.

2) we ALWAYS! underestimate the future.

Jeremiah Alexander, inventor, mechanic, electrical tech, computer guru andpersonal trainer

maddenedscientist 05/11/08 at 1:36 amwho knows what goes on in the world of black technology? It is secreted fora reason. Unfortunatly, that reason is, supposedly and hopefully,technological surprise in aiding defence against armed attack from other,hostile nations! call me an optimist. Its kinda sad that radicals who may ormay not be muslims, radical muslims, extremeists, or terrorists should wantto harm others (but let it be noted, not all zealot extremists are what theysay they are, or follow the tenents of thier claimed faiths. Thake theMountain Meadow Massacre. Radical Mormons, in clear and distictdefiance of the tenants of thier faith, murdered hundreds, and redistributedthier children...... sickening. But it was not thier religion that made them doit. It was themselves)Also, interesting parallels w/ the SPARTAN armor. Reminds me of theActive Defence System thingy the military now has. I see it in an article inthe area newspaper, and a few years later, i see it on the TV showFutureWeapons. And someone i lived with thought it was a misinformationthing by the military. What if this Spartan thing is information disseminationin a similar manner? bizarre theory, but plausibe in a certain light. By theway, has anyone heard of the A46? if you dont know, dont ask....


sketchy J 05/11/08 at 5:16 pmIt seems likely to me that this technology could be used as the human endof a device to control a robot in the field. The human would see and hearwhat the robot does and it could use force feedback. The movements couldbe controlled wirelessly so that the operator could be miles away from therobot in the field.


maddenedscientist 05/12/08 at 12:11 amfascinating idea Sketchy J. But what about signal lag, limited sensoryscope, and overall lack of total human sensation? Takes a human to takecare of a human's interest. Though i love robots. They are very cool. Theone problem i have is with the name. Comes from a Latin, greek, or romanword for "slave"


3lfd3wd 05/15/08 at 6:02 amI hate to be an arse, but the parallels with the Spartan armour are all welland good, but the powered suit idea has been around for alot longer thanthat in computer games, Half-life, released 3 years before Halo, has apowered suit that the player wears that stores weapons, allows firing ofmuch larger guns than a standard man, enables longer jumping, armourfrom bullets, etc etc.

The earliest game character I can think of off the top of my head was therobotic-suited equipped Hitler in Wolfenstein 3D from 1992!


Choirclown 05/15/08 at 5:54 pm"We are the Borg. You will be assimilated. Resistance is futile"


hagamablabla 05/29/08 at 1:20 amThe cross section showing about when parts of the suit would be made...what really caught my attention was the health bar on the screen. AFREAKING HEALTH BAR! The military has decided to make life a videogame now. Still, that's a ingenious invention


newgsm 06/11/08 at 5:59 pm - - -


RevizeSkeptix 07/05/08 at 12:29 am Link to this comment


10 of 16 09.07.2013 16:36

Darn son that Fatching awesomei want that suit

sniperfora 07/11/08 at 2:31 pm

18


SolarWarrior

07/22/08 at 9:45 pmwell, ischlesi...you seem to have covered exactly what i was going to say...(thanks-you saved me from needing to type that long of a paper). That wasa GREAT idea about making the suit crawl away from the battle to seekmedical attention for the soldier inside. Normally i'd put in some counterpoint or whatever..but ,like i said before, you got it all for me. thanks.

c-ya l8er


ghettocheeze 08/07/08 at 3:17 pmLooks like a more realistic possibility of a Master Chief than Tony Starkblasting into hypersonic speeds. Could happen within 30 years. Armor cladskeleton with movement at every joint and the flexibility to maneuver on thebattlefield. Halo tech is not very far off and may happen within our lifetime.


crysan 08/13/08 at 4:39 ami suggest that they should replace those funny hands of the exoskeletonthat looked like pliers or what. I've read about those polymers that tightenup when fired with electricity. i guess it would give much strength to the suitto carry heavy things since those rubber experts may develop that rubberwith excessive strength and endurance that it will not tear up once it carriesa heavy object.

if they are indeed building a suit, don't mind that "Iron Man" stuff. build fromwhat you have right now.

and next stuff, should the helmet be like the one on a kind of helicopter theUS has. the one that makes the machine gun move following the samedirection from where the pilot is looking. i guess you guys can make ahelmet that would respond to the movement of the eyes.

and the suit itself, i think it would be better if you will use the strongest butthe lightest metal the earth has right now.

about the flying stuff, i'm still trying to figure out an environment friendlysolution. LOL

i have my own design and you bright minds of the world can contact me. iguess i can do it if all scientists would help. hehe'


Cruise Control ... 08/19/08 at 3:15 amNot that I want to be rude or sound like a jerk (or super duper duper nerdy)but its actually called MJOLNIR (Pronounced Mole-ner [something alongthose lines, the J is silent though]) armor (after Norse Mythology, or morespecificly, Thors Hammer), not spartan armor, Which was their finalweapon to fight against the convenant (when i say final weapon, read thebook, they get biological enhancements, which is described, I believe, asweapons to fight the convenant, from doctor halsey, and her final 'gift' wasthe armor).

Spartan II (thats there correct codename) more more or less just a codename for the program of training them since there young age to when theywere 'combat' ready.

I could go into a really big detailed story on them, but I'll save everyone thepain of hearing me talk about Halo.

Also, there are aspects of the MJOLNIR Armor that might take more the5-30 years to make, but i could be wrong, but the amount of energy to usedto power the suite is a rediculous, the writer of the halo book actuallydescribes why the previous suites didnt work and why the new ones did(Refrence: Halo: The Fall of Reach, and Halo: First Strike), suites like thiswould most likely need to be close to a field generator (did anyone noticethe big power cord coming out of the guys armor [the armor from the actualarticle btw]), but the book could be totally scifi-ing it out, but his pointsseemed to make sense. A shield, well, i dont know if something like thatwill happen overly soon.

To 3lfd3wd:

While I'm not as adept at the Half Life, I'm pretty sure that his suite was justmeant to handle radiation, and heavy lifting for the crystal type object at thebegining of Half Life, it just happened to be convient that it helps him kicksome bad guys face in, I also think that it wasnt really thought through (I



11 of 16 09.07.2013 16:36

could be wrong on this one) about carrying multiple weapons, if you look athis armor, it wasnt designed to carry weapons, it was designed for radationand all that I mentioned before. While the actual MJOLNIR armor wasactually designed for a battle.

But then again, i could totally be wrong, but i think thats how it goes. (Itsalso late here, so I could totally be blundering around here)

PS my ideas are based off of reading the halo books and picking up thingsfrom reading, i have not done enormous amounts of reading into this stuff,if i made an error, point it out to me, just dont rip me apart please, thanks :)

Caps Lock is cruise control for cool

The One 09/24/08 at 6:39 pmWELCOME to the REAL HALO


bbruening41

10/31/08 at 1:46 amok hopefully we are done talking about halo which is based i believe first inthe video games and then backed up by the books. But the idea firstoriginated back in the 60s in a book from an old guy who had no idea abouthalo, the convenant, brs, plasma rifles and such. don't get me wrong thesimilarities between the XOS and Halo are very similar. And i am notputting Halo down or anything, i am a gamer to and i play as well.

The XOS inventor, jacobsen, probably grew up reading the Ironman comicsand that is probably one of the places he got his idea from and the rest of itjust compliments XOS. And do you really think he ripped his idea off ofHalo? The guy was an adult when Pong came out.

Now to the aspect of the XOS itself. The helmet is already being design bythe military for jet pilots so they dont have to rely on pure eyesight to keepand eye on the enemy that dropped in behind them they can just look inbehind and satellites send info to the helmet as to where the enemy andshows up on the pilots HUD. To mwesty64, the hydraulics are not outdated,they are very useful. I am always using hydraulics for ideas because theyare such a good base and can you give me any other things that can lifthuge masses for construction that do not use hydraulics. I think a goodidea for the next version should be electric motors however youcompromise the strength of the suit. But another would be magnetic jointsso as to reduce friction to nil and more power would be directed to strength.

The only power i see for this suit is the power as mentioned earlier. Until away to power the suit well and for long periods of time is perfected we willnot be seeing any power suits for a long time to come. But who reallyknows how long that will be until that time does arrive.

I just ask that we stop comparing this reality, the XOS, to the fictional Halo.We can compare all we want but dont we want to try to make this a realitysooner and put out ideas. We act as a filter for these inventors we catchthe stuff they dont see.

Congrats to Jacobsen for the first major step on the road to a betterintegration between man and machine.


LTIUAFO 11/03/08 at 5:27 pmJohn Steakly-------->ARMOR

Powered armor coupled with AWESOME Martial Arts!!


thinkforward 01/22/09 at 4:03 pmArmy of the Future: "Consider just the potential changes that might effectthe infantryman. Future soldiers may operate in encapsulated, climate-controlled, powered fighting suits, laced with sensors, and boastingchameleon-like 'active' camouflage. 'Skin-patch' pharmaceuticals helpregulate fears, focus concentration and enhance endurance and strength.A display mounted on a soldiers helmet permits a comprehensive view ofthe battlefield in effect to look around corners and over hills and allowsthe soldier to access the entire combat information and intelligence systemwhile filtering incoming data to prevent overload. Individual weapons aremore lethal, and a soldiers ability to call for highly precise and reliableindirect fires not only from Army systems but those of other services allows each individual to have great influence over huge spaces. Under the'Land Warrior' program, some Army experts envision a 'squad' of sevensoldiers able to dominate an area the size of the Gettysburg battlefield where, in 1863, some 165,000 men fought" (p. 62).


Dr.Dimbo 04/17/09 at 10:15 pmThat has to be one of the WORST exoskeletons I either thought of or seen.There is not much protection and not verystrong at all. The military needs to rethink its standards.



12 of 16 09.07.2013 16:36

True 05/08/09 at 7:42 amI'm impressed! Iron Man for all.

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martin20 05/30/09 at 3:20 amI think idea is good and maybe not a perfect but it is still a beginning /inprogress I mean/.Maybe when that apparatus have more good connectionwith human body and they work in symbiosis...

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WhiteZombie7689 06/12/09 at 11:56 amSo, most of us are agreed that the concept has been around for years.That's great, but detracts from the fact that Mr. Jacobsen is actually tryingto build a working model.

To those who criticize, hydraulics won't be used in the final product.According to online sources, Raytheon will be using some sort ofcontractive, metal bands (synthetic muscles, so to speak.) Mr. Jacobsen istrying to make something better than what already exists. HAL 5 only has5:1 gain, while the proposed XOS has a 10:1 gain. The only question nowis how to power it.

The only suggestions I have are: use actual gloves that are powered andput light-weight, tempered, composite armor on it with ceramic interiorplates and insulated processors and servos. They probably will, but I had tomention it.

"When I examine myself and my methods of thought, I come to theconclusion that the gift of fantasy has meant more to me than my talent forabsorbing positive knowledge."

-Albert Einstein


gena 07/21/09 at 3:48 ammetal bands (synthetic muscles, so to speak.) Mr. Jacobsen is trying tomake something better than what already exists.http://www.crazypurchase.com


crystallover 09/10/09 at 11:02 pmhe only suggestions I have are: use actual gloves that are powered and putlight-weight, tempered, composite armor on it with ceramic interior platesand insulated processors and servos. They probably will, but I had tomention it.

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mouses 11/22/09 at 5:33 amIn many hollywood film Iron man just make the war with many countries. Ido not like this kind of weapon.www.ezeen.net


dubbyd 12/11/09 at 5:20 pmGreat article! www.r-a-c.ro


osmoz 01/13/10 at 11:25 amIn many hollywood film Iron man just make the war with many countries. Ido not like this kind of weapon.izgi film www.cizgifilmclub.com



13 of 16 09.07.2013 16:36

MMr 01/17/10 at 8:28 amThat has to be one of the WORST exoskeletons I either thought of or seen.There is not much protection and not verystrong at all. The military needs to rethink its standards

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Jazzy Breeze 05/11/10 at 11:02 pmThis is amazing technology! Where to next? Some of the fantasies we haveas children are becoming a reality. Unreal!! This technology is potentiallylife changing for some with significant disabilities. To consider suchtechnology as a potential for supporting the everyday needs of people withbody dysfunction is exciting and exhilarating.

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cheapdesignershop 09/30/10 at 5:16 amI guess its pretty easy to talk about the use of such power suits to defendthe United States and give our troops the best protection and firepower asa waste when your sitting safe




14 of 16 09.07.2013 16:36

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dalemcleod

06/15/11 at 7:40 amThe comic book inspired by the real man is a very interesting topic. Thesecret mountain lab to make the mechanical superhuman is simply greatand more than just a fantasy with the XOS Exoskeleton. Thanks for sharingthis info with us! [url=http://www.personalchecksfast.com/]OrderChecks[/url]


dalemcleod

06/15/11 at 7:42 amThe comic book inspired by the real man is a very interesting topic. Thesecret mountain lab to make the mechanical superhuman is simply greatand more than just a fantasy with the XOS Exoskeleton. Thanks for sharingthis info with us!

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BlankGuy

08/11/11 at 7:16 pmCOOL!

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yelstin

05/16/12 at 9:20 amany one plzz contact me i can build this plzz



16 of 16 09.07.2013 16:36

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