The field of ergonomics has been significantly shaped by the advent of evolving technologies linked to new industrial paradigms, often referred to as Industry 4.0 (I4.0) and, more recently, Industry 5.0 (I5.0). Consequently, several studies have reviewed the integration of advanced technologies for improved ergonomics in different industry sectors. However, studies often evaluate specific technologies, such as extended reality (XR), wearables, artificial intelligence (AI), and collaborative robot (cobot), and their advantages and problems. In this sense, there is a lack of research exploring the state of the art of I4.0 and I5.0 virtual and digital technologies in evaluating work-related biomechanical risks. Addressing this research gap, this study presents a comprehensive review of 24 commercial tools and 10 academic studies focusing on work-related biomechanical risk assessment using digital and virtual technologies. The analysis reveals that AI and digital human modelling (DHM) are the most commonly utilised technologies in commercial tools, followed by motion capture (MoCap) and virtual reality (VR). Discrepancies were found between commercial tools and academic studies. However, the study acknowledges limitations, including potential biases in sample selection and search methodology. Future research directions include enhancing transparency in commercial tool validation processes, examining the broader impact of emerging technologies on ergonomics, and considering human-centred design principles in technology integration. These findings contribute to a deeper understanding of the evolving landscape of biomechanical risk assessment.

Musculoskeletal disorders (MSD) encompass a variety of conditions affecting muscles, joints, and nerves. In Portugal, MSDs are the most prevalent occupational health problem in companies. Based on the relevance of work-related MSD (WMSD), this study aims to assess the prevalence of MSD complaints in a needle manufacturing industry in Northern Portugal, following a cross-sectional approach. Thus, 526 workers from five departments (i.e., operator, tuning, maintenance, administration, and logistics) answered a sociodemographic questionnaire and the Nordic Musculoskeletal Questionnaire (NMQ). Within the last 12 months, females exhibited a higher frequency of complaints than males across all body parts except for ankles/feet. The body parts eliciting the most percentage of complaints for both genders include the lower back (54.2%), neck (42.2%), shoulders (39.0%), ankles/feet (38.2%), and wrists/hands (35.7%). No significant association was found between Body Mass Index (BMI) and body part complaints. Tuners reported the highest complaint rate, with occupations as substantial predictors of complaints in certain body parts. Likewise, complaints tend to increase with age. The findings advocate for ergonomic interventions that are gender-, age-, and job-sensitive.