Personalized seating solutions for truck drivers
Reducing musculoskeletal disorders & discomfort with the use of 3D-printed seat inserts
B.T. Steenhuis (TU Delft - Industrial Design Engineering)
Y. Song – Mentor (TU Delft - Industrial Design Engineering)
Mehmet Ozdemir – Graduation committee member (TU Delft - Industrial Design Engineering)
A. Anwar-Hameed – Graduation committee member (Perfect Fit Upholsteries)
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Abstract
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.