Custom Anatomical Seat Cushion Design Without Negative Molds
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Solution Overview
Problem
Current methods for designing custom anatomical seat cushions are lengthy, costly, and limited in customization, often requiring negative molds that cannot be easily modified, which hinders the creation of personalized and efficient solutions for patient comfort and rehabilitation.
Innovation Solution
A machine-assisted method that captures anthropometric measurements to generate a 3D CAD model of a user's buttock shape, allowing for detailed customization without molds, using additive technology like 3D printing to create a customized seat cushion that can be tailored to specific clinical needs and preferences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional negative molds are used to create custom seat cushions, then the preliminary shape can be determined, but the process becomes lengthy, costly, and the molds cannot be easily modified once created
Solution Approach 1:
The patent uses 3D scanning to create a digital copy of the patient's body surface geometry, replacing the traditional physical negative mold. This digital model can be stored, modified, and reused without the time and cost constraints of physical molds, while maintaining precise anatomical replication for custom cushion design
Solution Approach 2:
The patent replaces the mechanical mold-making process with computer-aided design (CAD) software that operates on digital 3D scan data. This substitution eliminates the need for physical mold fabrication and allows rapid iteration and modification of cushion designs through software operations rather than manual mold adjustments
2Ease of manufacture
If traditional molding methods are used, then a preliminary cushion shape can be achieved, but the number of customizations that can be applied is limited
Solution Approach 1:
The patent creates a dynamic design process where the digital 3D model and CAD parameters can be adjusted in real-time based on changing patient needs. The system allows for dynamic modification of cushion geometry, material distribution, and support characteristics without requiring new physical molds, enabling unlimited customization options
Solution Approach 2:
The patent utilizes parameter-based CAD modeling where cushion characteristics such as density, thickness, contour shape, and support zones can be independently adjusted through numerical parameters. This allows for precise control over multiple customization aspects simultaneously, far exceeding the limited variations possible with traditional molding
3Reliability
If custom molded cushions are manufactured using traditional methods, then patient-specific anatomy can be accommodated, but the process is costly and time-consuming
Solution Approach 1:
The patent performs preliminary 3D scanning and digital model creation before any physical cushion manufacturing. This advance digital preparation allows for complete design finalization and validation before production, eliminating iterative mold adjustments and ensuring the first manufactured cushion is optimal, thereby improving both reliability and productivity
Solution Approach 2:
The patent replaces the slow, manual mold-making and cushion fabrication process with automated digital design and modern manufacturing techniques. The CAD model can be directly used for CNC machining or 3D printing, dramatically increasing manufacturing speed and efficiency while maintaining or improving cushion quality and patient-specific fit
Data Source
AI summary
A machine-assisted method of manufacturing a customized anatomical seat cushion for a user is provided, the method comprising the steps of capturing anthropometric measurements of the user in a seated position; inputting the captured anthropometric measurements in a three-dimensional (3D) computer-aided design (CAD) model to reproduce buttock of the user; generating a 3D anatomical seat cushion representation fitting the shape of the user based on the 3D CAD model of the buttock of the user; and machining a support structure according to the generated 3D anatomical seat cushion.