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

• Customized office chair cushions are designed based on detailed anatomical 3D scanning for enhanced ergonomic support. • The study leverages advanced 3D modeling and additive manufacturing to achieve precise, user-specific cushion contours. • A structured prototyping process using material extrusion (MEX) ensures high durability and comfort without requiring post-processing. • Comparative 3D scanning validates improved posture with customized cushions over standard ergonomic setups. • Custom cushions effectively support user-specific ergonomics, providing a potential approach for targeted health and comfort solutions in office seating. 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.