Advanced Wheelchair Headrest.

In collaboration with Carbon, we designed an advanced wheelchair headrest that addresses the comfort, hygiene, and usability limitations of traditional solutions.

Conventional wheelchair headrests are typically made from rigid plastics or foam wrapped in vinyl. While functional, these designs often provide uniform support that fails to accommodate individual anatomy, leading to pressure points, poor posture, and discomfort during prolonged use. Additionally, non-breathable surfaces can trap heat and moisture, raising hygiene concerns – particularly in clinical or long-term care environments.

To overcome these challenges, the headrest was developed using Carbon’s EPU 45 elastomer. This material enabled the creation of a lattice-based structure that delivers targeted support in key areas such as the occipital region and upper cervical spine, while remaining compliant where flexibility is required. The result is a headrest that better distributes pressure and improves overall user comfort.

EPU 45 also offers significant hygiene and durability benefits. Its open lattice structure promotes airflow, improving breathability and reducing heat buildup during extended use. Unlike traditional foam, EPU 45 is resilient, tear-resistant, and easy to clean, making it well-suited for medical and assistive applications where cleanliness and longevity are critical.

By combining ergonomic design principles with advanced additive manufacturing materials, ITERATE and Carbon demonstrated how EPU 45 can redefine comfort, performance, and hygiene in wheelchair support systems.