Design and milling manufacture of polyurethane custom contoured cushions for wheelchair users

Silva, Fábio Pinto da; Beretta, Elisa; Prestes, Rafael Cavalli; Kindlein, Wilson

doi:10.4066/amj.2011.963

Cited by 6 publications

(4 citation statements)

References 12 publications

(9 reference statements)

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“…The saving in labour time occurs in the early stages of the process where less manual labour is required to produce the initial foam shape. 23,28 CNC foam carved systems are upholstered after production in the same manner as other custom foam seating systems.…”

Section: Cnc Foam Millingmentioning

confidence: 99%

“…Typically, the product of the CNC milling process requires the same amount of manual refinement as foam systems produced through non-digital methods. The saving in labour time occurs in the early stages of the process where less manual labour is required to produce the initial foam shape (29,34). CNC foam carved systems are upholstered after production in the same manner as other custom foam seating systems.…”

Section: Seat Completionmentioning

confidence: 99%

“…An aspect of CNC milling for manufacturers to consider before implementing is that employee training on CAD/CAM software and certification with CNC milling machinery may require additional financial and time commitment.. Also, 5-, 6-and 7-axis robot arms, which are required to achieve seat production in one tool path (without the need to re-orient the foam block manually during CNC milling), can be quite costly at over €300,000 for a 5axis machining centre, not including CAD/CAM software. However, simpler machines with 3 axes can be used with a relatively high accuracy of contours in the final seat (around ±2mm resolution), depending on the milling direction, spindle speed, and feed rates of the CNC milling paths (29,34,38). The cost of these 3-axis machining centres is upwards of €60,000, not including CAD/CAM software.…”

Section: Strengths and Limitationsmentioning

confidence: 99%

“…However, simpler machines with three axes can be used with a relatively high accuracy of contours in the final seat (around ±2 mm resolution), depending on the milling direction, spindle speed and feed rates of the CNC milling paths. 23,28,32 The cost of these three-axis machining centres is upwards of €60,000, not including CAD/CAM software.…”

Section: Strengths and Limitationsmentioning

confidence: 99%

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Manufacturing custom-contoured wheelchair seating

Nace

Tiernan

Annaidh

2019

Prosthetics &Amp; Orthotics International

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Background: Custom-contoured wheelchair seating lowers risk of pressure injury and postural deterioration while custom-contoured wheelchair seating lowers risk of pressure injury and postural deterioration while increasing the stability and functional activity of the wheelchair occupant. Producing custom-contoured seating systems has historically been a labour-intensive process custom-contoured seating systems is historically labour-intensive. Objectives: Evaluate the strengths and limitations of current manufacturing processes for custom-contoured wheelchair seating to suggest potential future manufacturing processes. Study Design: Literature review of the state of the art. Methods: Research conducted through a literature review focused on the performance of different types of custom-contoured wheelchair seating products and processes over the last 40 years. Recent literature in orthotics and prosthetics was also consulted to assess future trends in seating. Results: There are five main manufacturing processes currently used to produce custom-contoured wheelchair seating systems. No single process is yet suitable for all wheelchair users, but many manufacturers are transitioning to computer numerical controlled (CNC) milling to reduce manual labour. Adjustable micro-modular seating and moulded seat insert manufacturing are also prevalent and offer alternative seating to soft foam carving. Conclusion: There is a need in the custom wheelchair seating sector for processes that are fast, cost-effective, produce little to no material waste, and that can effectively maintain a comfortable seating micro-climate. Additive manufacturing may meet these criteria, but further evaluation is required. Clinical relevance This review suggests that the custom-contoured wheelchair seating manufacturers are moving away from labour-intensive processes towards digital techniques, like CNC foam milling. Additive manufacturing is a potential new process that may reduce overall costs, the lead time in preparing seats and has the potential to better manage the seating micro-climate.

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Section: Cnc Foam Millingmentioning

confidence: 99%

Section: Seat Completionmentioning

confidence: 99%

Section: Strengths and Limitationsmentioning

confidence: 99%

Section: Strengths and Limitationsmentioning

confidence: 99%

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Manufacturing custom-contoured wheelchair seating

Nace

Tiernan

Annaidh

2019

Prosthetics &Amp; Orthotics International

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Analysis of the influence of the seat foam density in the posture of hemiplegic wheelchair users using computerized photogrammetry

et al. 2020

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The use of a wheelchair after a stroke is often necessary, and this device can assist in support and proper positioning in sitting posture. However, there is not much scientific evidence proving the benefits of adaptations in wheelchairs for individuals with a motor and sensory impairments, mainly those with hemiplegia. The aim of this study is to assess whether adaptation with foam of different densities is effective in improving the sitting posture of hemiplegic wheelchair users. The study was carried out on 18 participants (seven female and eleven male), hemiplegics, wheelchair users and with an average age = 61. The computerized photogrammetry technique was used to analyze the posture of the participants sitting in foams of different densities. In order to perform the statistical analysis, the Shapiro-Wilk hypothesis test was used to assess the normality of the data. The results highlight the improvement not only in pelvic alignment, but also the trunk and head using different combinations of density foam seats. In addition, the results suggest that the use of densities 33 kg/m 3 and 40 kg/m 3 is sufficient to have a better body alignment.

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