Musculoskeletal disorders (MSDs) are a persistent occupational hazard among professional drivers, particularly truck drivers, due to prolonged static postures, whole-body vibrations, and poor seat ergonomics. These issues contribute to discomfort, sick leave, and long-term health deterioration. This study aimed to develop, prototype, and evaluate a personalized seating solution that addresses these risks through the use of 3D scanning and 3D printing technologies.   

Over a 20-week research period, custom seat inserts were created using anthropometric  data and vacuum cushion imprints, which were digitally modeled and 3D-printed using  flexible TPE filament. The inserts were both fitted in and tested in a simulated truck cabin  with 17 participants, using a combination of pressure mapping and short-term comfort  questionnaires.   Quantitative results showed a 39.2% reduction in average pressure, 18.1% reduction in peak  pressure, and a 15.1% increase in contact area when using the inserts. Subjective comfort  ratings significantly improved in regions under the thighs, buttocks, knees, and neck (p <  0.05). Observational data revealed enhanced postural stability and anthropometric fit, though  backrest comfort varied due to human error in production tolerances.   These findings demonstrate the feasibility and ergonomic benefits of integrating additive  manufacturing into personalized seating interventions for occupational drivers. While short-term results are promising, future research should evaluate long-term effects under real-world driving conditions, including the impact on whole-body vibrations and MSD progression. The study contributes to the growing field of parametric ergonomic design and supports the application of human-centered additive manufacturing in the transportation and seating industries.