Ergonomic design and evaluation of woodworking chisel

BackgroundChiselling involves repetitive, precision work with constrained postures and high hand loads, contributing to upper-limb musculoskeletal disorders among artisans. Despite extensive work on workstation ergonomics and general hand-tool design, few studies have systematically translated ergonomic risk-assessment findings into specific chisel-handle design requirements and evaluated the resulting intervention in a real craft-sector setting.ObjectiveThis study aimed to characterize ergonomic exposures in chiselling, translate these findings to concrete handle design requirements, and evaluate a prototype handle's short-term usability versus conventional handles.MethodsFifty male artisans underwent NMQ, palm pain mapping, RULA and ART assessment. Risk findings informed a modular ergonomic handle (elliptical contour, 25-40 mm diameter, 10-15° cant, strike ferrule). A counterbalanced in-lab within-subject short-term usability comparison (n = 30) was conducted alongside post-trial acute hand pain mapping and targeted ART posture sub-component reassessment.ResultsA high prevalence of upper-limb musculoskeletal symptoms and dominant-hand biomechanical risk were identified. The prototype was strongly preferred and rated easier and more comfortable to use, and it markedly reduced acute pain at the thumb base and first finger-web. Usability improved across all items and acute thenar/first-web pain fell substantially (Zones 19-20, paired d > 2.9), with parallel reductions in the wrist-posture and force-demand sub-components of the ART assessment.ConclusionsRisk-informed handle redesign yielded immediate, objectively corroborated hand-level benefits. The study contributes a low-cost, retrofittable ergonomic chisel handle and replicable risk-to-design pathway applicable to woodworking artisans and similar occupations. Longitudinal field validation is necessary to establish sustained reductions in musculoskeletal disorder prevalence and productivity gains.