Programmable foam: 3D printing brings progress in the production of seating aids

At this year’s Rehacare trade fair, a consortium of experts and companies will be presenting the innovative product ‘Programmable Foam’. This is a 3D-printed thermoplastic alternative to conventional foam that has been specially developed for customised 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 orthopedic technician with the RAS Team in Melle, Germany, highlights the advantages: “Programmable Foam will overtake part of the crafting from traditional foam and improve many applications. I have so many ideas for improving seating aids with this technology, and we are just starting. First, how it handles moisture is good news for sweating patients and a great help for patients with incontinence issues. The moisture is transported away from the body to be cleaned, and the seat is easy to clean and dry.”

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

“When we onboard a customer, we guide them through every step,” says CEO Jacob Nissen. “We review models and g-codes, provide technical advice, and ensure that orthopedists can focus on crafting the perfect custom product for their patients. The story of Bernd 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 customised solution solved the moisture problem that had long caused him pain and discomfort.

Sustainability also plays a key role. By using 3D printing technologies, less waste is produced than with conventional foams, which is in line with the EU’s climate targets. At Rehacare, visitors can see a direct comparison of the two manufacturing processes in Hall 4 E30 and convince themselves of the advantages of the 3D-printed alternatives.