Enhancing ergonomic comfort: A study on customized cushion design using 3D scanning and additive manufacturing

This paper presents a method for designing a customized ergonomic office chair backrest aimed at improving user posture and long-term health. Given the importance of ergonomics in workplace settings, this study leverages 3D scanning and additive manufacturing to create personalized cushions that conform precisely to individual anatomical shapes, aligning with ergonomic standards. The process begins with high-resolution scans of both the user's back and a standard chair backrest, followed by cushion modeling in Blender to ensure exact fit and support. Additive manufacturing was selected for cushion fabrication, using a TPU material with an optimized internal structure to enhance comfort. Results indicate a notable improvement in posture alignment and comfort, verified through comparative scans before and after customization. The custom backrest also encourages proper posture through a postural retraining effect and provides a high level of hygiene due to its non-porous material. While this customization method is best suited for individual users rather than shared work environments, it offers a viable, cost-effective solution for ergonomic enhancements in office seating.