Plastics in Wheelchairs: Material Design for Greater Comfort and Mobility

In modern wheelchairs, plastics serve far more purposes than providing structural support or shaping components. They can distribute pressure, manage moisture, integrate sensors, dissipate heat and enable compact designs. Two recent examples illustrate how material development, additive manufacturing and processing technologies can improve both the mobility and quality of life of wheelchair users.

In the StopUlcus research project, six partners are developing a customisable wheelchair seat cushion that combines 3D-printed lattice structures with polymer foams. The aim is to better prevent pressure ulcers in wheelchair users and support the healing process of existing wounds.

Plastics play a central role in this approach. The cushions are designed to be individually tailored in terms of shape and firmness. While 3D-printed structures allow precise control of mechanical properties, polymer foams contribute to comfort, pressure distribution and moisture management. In addition, an integrated sensor system is intended to monitor pressure and moisture levels and provide recommendations for necessary position changes.

The project highlights the growing importance of combining additive manufacturing, material development, sensor technology and digitalisation for the next generation of medical assistive devices. Linking patient-specific data collection, simulation and plastics-based manufacturing creates the foundation for customised seating solutions.

Funded by the German Federal Ministry of Research, Technology and Space (BMFTR), StopUlcus brings together expertise in materials science, additive manufacturing, sensor technology, data processing and clinical research. The project partners – Klinikum Bayreuth GmbH, Softline-Schaum GmbH & Co. KG, cirp GmbH, Sanitätshaus Urban & Kemmler GmbH, Konzept Informationssysteme GmbH and the Fraunhofer Institute for Manufacturing Engineering and Automation IPA – collectively cover the entire value chain, from research and manufacturing to clinical application.

Plastics also play a key functional role in electric wheelchair drive systems. For a manufacturer of electric wheelchairs, WEVO-CHEMIE developed a thermally conductive polyurethane potting compound for stator encapsulation.

The material performs several functions simultaneously: it provides electrical insulation, supports reliable processing and transfers heat from the copper conductors to the motor housing. As a result, temperature peaks that can occur when wheels become blocked can be managed more effectively. Its low viscosity also enables void-free impregnation of the stator windings.

This example demonstrates the importance of application-specific plastics formulations for compact mobility solutions. Rather than focusing on maximum material performance values alone, success depends on balancing polyurethane properties, thermal conductivity, processing requirements, installation space, serial production and cost-efficiency.

Both examples underline that plastics improve wheelchairs in ways that go far beyond lightweight construction and design flexibility. They enable new functionalities directly within components – from personalised seating systems to thermally stabilised electric motors.

For the plastics and rubber industry, this opens up important fields of development, including customised components, smart materials, integrated sensor technology, additive manufacturing and reliable solutions for serial production. Particularly in medical technology and mobility applications, these developments demonstrate how closely material innovation and application expertise must work together to translate plastics-based solutions into tangible everyday benefits.