Designing for adoption: a culturally grounded, 3D-prototyped ergonomic hand tool for Andean potato harvesting

Abstract

Small-scale potato harvesting in the Peruvian Andes relies on traditional hand tools that were not designed with ergonomic or user-centered principles. Farmers therefore face high physical demands, awkward postures, and increased risk of work-related musculoskeletal disorders. This study presents preliminary findings from the Discover and Define phases of a mixed-method project, guided by the 'Double diamond' design model, to develop an ergonomic harvesting tool. Physical evaluations and interviews with 12 rural farmers explored perceptions, needs, and cultural requirements for adoption. Anthropometric, hierarchical task analysis (HTA), and a Rapid Entire Body assessment (REBA) characterized tasks and postural risk. Surface electromyography (sEMG) measured muscle activation during traditional tool use, and a standardized comfort scale captured perceived discomfort. Farmers (49 years; IQR:45.5-54.0; 50% women) emphasized local repairability, similarity to familiar tools (e.g., picks and allachu), and easy of transport by hand and pack animals for adoption.HTA identified soil digging as the highest-risk subtask. REBA classified 83.3% of participants as high postural risk. sEMG showed elevated activation of the extensor carpi radialis (143.6 ± 56.8 µV) and biceps brachii (118.6 ± 53.3 µV). Mean overall comfort rating was 38.7 ± 7.2. These insights informed concept generation and rapid iteration from cardboard prototypes to a 3D-printed mock-up. The current design includes a telescopic handle adjustable from 84–90.5 cm and an ergonomic grip diameter of 39–41 mm, accommodating 80% of the sample, while preserving functional familiarity through a dual head with a 21.5 cm tip and blade. Prototype evaluation in field-like trials is underway.

Keywords: 3D Printing, Ergonomic, Human Factors, Mixed-method Study, Agriculture

DOI: 10.54941/ahfe1007799