Humans vs. Digital Models: Why Human Feedback Still Matters in Product Development

In the fast-paced world of product development, Digital Human Models (DHMs) and CAD (Computer-Aided Design) systems are invaluable tools. They allow us to visualize, simulate, and design products efficiently. However, relying too heavily on these technologies without consulting actual people can be a costly mistake.

While DHMs are great for getting us close to the desired design, they aren’t perfect, especially when it comes to accounting for the human experience. Here are a few real-life examples where human feedback revealed flaws that DHMs missed:

1. “I know the computer model wears it that way, but I can’t. It won’t go there.”
   Just because it works for a digital model doesn’t mean it will work for a real person.
2. “This either interferes with my utility belt or chokes me, or both, depending on where it is adjusted.”
   DHMs often miss situational complexities like how something interacts with other gear or accessories.
3. “It feels like I’m in a tunnel, and it makes me uncomfortable or claustrophobic.”
   DHMs cannot replicate the psychological experiences or discomfort that people might feel when using a product.
4. “Something is jabbing me in the back of the head.”
   An unnoticed adjustment clip caused discomfort for real users, something a DHM would never mention.
5. “I can’t wear these. It’s fine standing up, but hurts when I sit or squat.”
   Fit and comfort vary depending on body position, a factor DHMs often fail to capture.
6. “Well, the DHM may say I should see something, but I don’t.”
   Vision, perception, and body dynamics in real life can differ greatly from a computer simulation.
7. “I feel stupid wearing this. You couldn’t pay me enough to wear this in public.”
   Human emotions and social factors—like how people feel wearing a product—are completely overlooked by DHMs.
8. “It feels like it will fall off if I move too fast, and it makes me nervous.”
   Stability and confidence in wearing a product are critical, but DHMs won’t express anxiety or discomfort.
9. “Yes, it slips a lot if I move too fast, but I like how it feels. The recommended size hurts.”
   Real feedback about sizing preferences can vary widely, something that CAD systems rarely accommodate.
10. “It’s uncomfortable, but I’d still buy it because it makes me look good.”
    Style can outweigh comfort for some, a factor DHMs are unable to weigh in on.

The takeaway? CAD systems and DHMs are great starting points, but they lack the ability to consider the psychological, emotional, and situational experiences of real users. Relying on these tools alone can lead to missed insights, costly design revisions, or even product failure.

While technology continues to improve, there’s currently no digital solution capable of replicating the full human experience—especially when it comes to preferences, discomfort, or even fashion choices. A quick round of real-world testing can help avoid significant setbacks and ensure the product you deliver truly meets the needs of your customers.

In some cases, as with examples 9 and 10, human feedback can even help you refine product sizes or avoid unnecessary variations, ultimately saving money and resources.

Bottom line: DHMs are valuable, but never underestimate the importance of human feedback in product development. It’s the missing piece that bridges the gap between good design and great user experience.

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