3D printing brings progress in the production of seating aids

At this year's RehacareAt the 2018 trade fair, a consortium of experts and companies presented the innovative product “Programmable Foam”. This is a 3D-printed thermoplastic alternative to conventional foam, which was specially developed for individually adapted seating aids. In addition to better pressure distribution, programmable foam also offers improved ventilation properties and higher hygiene standards, which is a great advantage for users with special medical needs.

Jan Warnke, an experienced orthotist in the RAS team in Melle, Germany, highlights the benefits: “Programmable Foam will take some of the craftsmanship from traditional foam and improve many applications. I have so many ideas for improving seating aids with this technology, and we are only at the beginning. First of all, the way it handles moisture is good news for sweaty patients and a great help for patients with incontinence problems. The moisture is transported away from the body and can be cleaned, and the seat is easy to clean and dry.”

In collaboration with the Irish 3D printing service provider LCS and the Dutch partner Shapemakers, the trade fair will show how the transition from subtractive to additive manufacturing can be integrated into existing work processes. The focus is on digital workflows that make customized seating aids more efficient and precise.

“When we bring a customer on board, we guide them through every step,” says CEO Jacob Nissen. “We review models and G-codes, provide technical advice and ensure that orthopedic surgeons can focus on producing the perfect customized product for their patients.” Bernd's story is a touching example of how technology can create the perfect synergy between patient needs and orthopedic care.”

An impressive example of the application of this technology is the story of Bernd, a patient whose quality of life was significantly improved by a 3D printed seating aid. The custom-made solution solved the moisture problem that had caused him pain and discomfort for a long time.

Sustainability also plays a key role. The use of 3D printing technologies produces less waste than with conventional foams, which is in line with the EU's climate goals. At Rehacare, visitors can see a direct comparison of the two manufacturing processes in Hall 4 E30 and see for themselves the advantages of the 3D printed alternatives.