PPE that doesn’t fit, doesn’t protect. As obvious as it may sound, this remains one of the biggest challenges in occupational safety. Discomfort, misuse, or even abandonment of personal protective equipment is often tied to poor fit — which ultimately undermines its effectiveness.
The Instituto de Biomecánica de Valencia (IBV) has taken this issue head-on with the development of a groundbreaking solution: Avatar 3D. Using technologies like 3D Avatar Feet, 3D Avatar Body, and DOMEscan, companies can now design and assign workwear and safety shoes that are truly adapted to each worker’s body — improving both protection and comfort.
In this article, based on an interview with Mercedes Sanchis Almenara, Director of Innovation – Wellbeing and Occupational Health at IBV, we explore how this technology is reshaping workplace safety from the ground up.
Interview with Mercedes Sanchis Almenara, IBV
How would you assess the evolution of occupational risk prevention in Spain since Law 31/1995 came into effect?
Before 1995, regulations around risk prevention were fragmented and largely ineffective. The Occupational Risk Prevention Law established a comprehensive regulatory framework that introduced key principles such as prevention, the rights and obligations of employers and employees, and an enforcement system. It undoubtedly marked a turning point that helped professionalize workplace safety and foster a real prevention culture across companies.
What do you see as the main challenges that still need to be addressed in this field?
One of the biggest ongoing challenges is ergonomics. While we’ve made significant progress since the law was passed, musculoskeletal disorders remain the leading cause of sick leave in Spain. That tells us there’s still much to do—especially in the design of workstations, tools, and work environments. It’s also crucial to improve the return-to-work protocols for employees affected by these conditions, ensuring their tasks are adapted to their functional capacities.
Beyond workstation design, in what other areas is IBV involved in improving workplace health?
Aside from ergonomic workplace design, we work closely with companies to improve Personal Protective Equipment. We use extensive anthropometric databases and analysis tools that allow us to develop design criteria tailored to real human characteristics. For instance, the LABOGÉNERO project integrates a gender perspective to ensure PPE and workwear are genuinely inclusive and effective. We’ve also worked on improving the fit and comfort of masks and harnesses—always keeping usability in mind.
The problem: PPE that doesn’t fit can’t protect
One of the most persistent gaps in occupational risk prevention is the use of poorly designed or ill-fitting PPE. When protective gear doesn’t conform to the worker’s body shape or size, it becomes ineffective—and may even cause discomfort or injuries. As a result, many workers end up not wearing it at all, putting themselves at unnecessary risk.
Mercedes Sanchis puts it simply: “PPE that doesn’t fit the body doesn’t protect. Worse yet, it can cause discomfort and rejection, increasing the risk of accidents or injuries.”
That’s why proper ergonomic and anthropometric fit isn’t a luxury or a matter of aesthetics—it’s an essential condition for health and safety.
IBV and technological innovation in PPE: Moving toward personalized design
In this scenario, IBV has positioned itself as a leader in applying technology to improve how PPE adapts to the human body. One of the center’s most cutting-edge developments is 3D Avatar technology, a suite of digital solutions that can accurately capture body dimensions to support the design, development, and fitting of workwear and safety equipment.
What is 3D Avatar technology?
3D Avatar technology combines full-body scanning, digital modeling, and anthropometric data processing to generate detailed 3D representations of the human body—or specific parts like the feet. This data is used both in the design phase and for automated product assignment, significantly improving fit and effectiveness.
IBV has developed three key tools in this area:
- 3D Avatar Feet: Digital foot scanning for better design and fitting of work footwear.
- 3D Avatar Body: Full-body characterization for workwear and complex PPE.
- DOMEscan/IBV: An advanced scanning system with both clinical and industrial applications.
Real-world results: Better fit, safer workers
The impact of this technology is already measurable. In the case of safety footwear, implementation of these tools has improved the correct size match rate by 30%. That means fewer issues like blisters, fatigue, or accidents—plus greater comfort and increased user compliance.
This model has also been applied to the design of masks, harnesses, and technical workwear, enabling data-driven, group-specific adaptations.
LABOGÉNERO and the importance of body diversity in PPE design
One of IBV’s most important projects is LABOGÉNERO, an initiative that introduces a gender and diversity perspective into ergonomic design for PPE and workwear. The project has clearly shown that male and female bodies exhibit significant morphological differences that must be accounted for to ensure real protection.
Using specific anthropometric data and field studies, LABOGÉNERO helps adjust sizing, patterns, and measurements to better fit a diverse workforce. This not only improves safety, but also promotes a more inclusive and equitable workplace.
A new era for occupational health: More personalized, more effective
Technologies like 3D Avatar are not only transforming how PPE is designed, but also how companies think about prevention and return-to-work strategies. The data generated allows businesses to anticipate risks, tailor their equipment, and provide solutions that meet each worker’s individual needs.
Because these are non-invasive and fully digital solutions, they can be seamlessly integrated into industrial workflows—reducing long-term costs and improving the sustainability of prevention systems.
Thirty years after Spain passed its Occupational Risk Prevention Law, the country has made major strides toward safer, healthier workplaces. But as Mercedes Sanchis points out, there is still work to be done—especially in ergonomics, human-centered design, and personalized protection.
With projects like 3D Avatar, LABOGÉNERO, and other in-house tools like Ergo/IBV or ergoIA, IBV is showing that prevention can no longer be reactive. Thanks to these innovations, occupational health is entering a new phase—one that is not only safer, but also more respectful of each person’s body and capabilities.
To learn more about these technologies and how they can transform your workplace, visit the official 3D Avatar site: https://www.avatar3d.tech