Salubrious brings 3D printed wheelchair cushions into serial production with Create It REAL's Programmable Foam
The Programmable Foam technology developed by the Danish Create It REAL makes a significant leap: from customization of orthopedic devices to serial production. The Swedish company Salubrious uses this solution for the AireRx line of wheelchair cushions, demonstrating that complex lattice structures in TPU can be standardized and produced in volumes compatible with healthcare tenders.
This shift marks a paradigm change for medical additive manufacturing. It is no longer just about extreme customization, but about using 3D printing for standardized series where internal complexity does not significantly increase costs.
From customization to series: the path of Programmable Foam
*Create It REAL has developed over the years a technology that simulates the behavior of foams through programmable lattices. Now this solution enters real-volume production.*
Programmable Foam is not a true expanded foam. It is a method for generating complex lattice structures via Fused Filament Fabrication in thermoplastic TPU. The material is deposited following geometric patterns that mechanically simulate the behavior of a foam.
The first commercial application involved custom orthopedic insoles. These devices require precise geometry to fit each patient's foot. The technology allowed producing small batches with unique geometries.
- Monolithic material: no gluing, no material change, no rigid edges
- Programmed design: consistent performance guaranteed by software
- Sustainability: low production waste, greater durability, material reuse
AireRx: wheelchair cushions with variable density zones
*The collaboration between Create It REAL and Salubrious has produced a line of cushions that integrates zones with different mechanical characteristics into a single printed component.*
Wheelchair users spend many hours seated. They require cushions that prevent postural and circulatory problems. Mass-produced cushions offer generic support, but customized solutions ensure superior benefits.
The AireRx line uses Programmable Foam to create zones with different compliance within the same component. By varying the lattice geometry and the deposition path, TPU can generate soft regions for pressure redistribution and stiffer ones for stability.
All this is achieved without assembling foam layers with different densities, glue, or inserts. The component is continuous and monolithic.
From prototype to healthcare supply chain
*The Salubrious project demonstrates that complex architectures can be standardized and produced in sufficient volumes for the healthcare market, including Swedish regional tenders.*
The collaboration between the two companies began several years ago. The goal was to develop a serial production process for AireRx cushions. After contracts awarded between late 2025 and early 2026, demand for the AireRx range has grown rapidly.
Create It REAL states that it has increased production capacity while maintaining the quality requirements of the process. This represents a concrete demonstration that large-scale production of 3D printed products is possible.
Programmable Foam uses Fused Filament Fabrication with thermoplastic TPU. The mechanical behavior is programmed through the geometry of the internal lattice, not through the chemistry of the material.
Implications for medical additive manufacturing
*The AireRx case shows a new model of 3D printing use: not only for unique devices, but also for standardized series where internal complexity justifies the additive process.*
Traditionally, medical 3D printing focuses on customized devices where each piece is different. The Salubrious project demonstrates that the same technology can be used for standardized products.
The advantage lies in internal complexity. Lattice structures with variable density zones would be difficult or impossible to produce with traditional methods. With additive manufacturing, this complexity does not significantly increase the cost of the individual piece.
Production has moved from custom to volumes compatible with healthcare tenders. This opens new scenarios for additive manufacturing in the medical sector, where standardization does not exclude geometric complexity.
article written with the help of artificial intelligence systems
Q&A
What is the Programmable Foam technology developed by Create It REAL?
Programmable Foam is not an expanded foam, but a method that generates complex lattice structures via Fused Filament Fabrication using TPU. The material is deposited following specific geometric patterns to mechanically simulate foam behavior.
What is the main application of Salubrious's AireRx line?
The AireRx line produces wheelchair cushions designed to prevent postural and circulatory issues in users who spend many hours seated. These cushions integrate zones with varying compliance within a single monolithic component.
How are different densities achieved in AireRx cushions?
Variable density zones are created by modifying the lattice geometry and material deposition path during 3D printing. This allows for soft regions to redistribute pressure and stiffer ones to ensure stability without assembly.
What are the main advantages of using Programmable Foam over traditional cushions?
Advantages include the product's monolithic nature, eliminating the need for bonding or material changes, and the absence of rigid edges. Furthermore, the process ensures consistent performance through programmed design and offers greater sustainability by reducing waste.
How does this project change the paradigm of medical additive manufacturing?
The project marks a shift from extreme customization alone to the serial production of standardized devices with internal complexity. It demonstrates that volumes compatible with healthcare tenders can be produced without geometric complexity significantly increasing costs.
