Kalogon Turns 3D Printing Into Custom Wheelchair Cushions

Wheelchair cushions have not changed much in decades. Most are off-the-shelf foam or gel blocks in a few standard sizes. Users adapt by adding cutouts or layering towels. A small Florida company called Kalogon is trying to replace that workaround with something printed to order.

Verro is a custom cushion line built with vat polymerization 3D printing. Each cushion is a lattice structure where density varies across the surface. Softer zones cushion bony prominences, firmer zones hold the pelvis in place, and the whole shape matches the user body rather than a size chart.

Why 3D Printing Changes the Fit

The problem with foam cushions is that they flatten under load. A person with a curved spine or pelvic obliquity ends up sitting on the wrong parts of their body for hours at a time. Pressure injuries, postural collapse, and chronic pain follow. Custom-molded cushions exist, but they are expensive, heavy, and slow to make.

Kalogon uses a sintered nylon or resin lattice that can be tuned in software. A scan of the user body determines where the cushion needs to give and where it needs to hold. The lattice geometry is then generated automatically and printed in one piece.

That process cuts the lead time from weeks to days. It also opens the door to Medicare reimbursement, which Verro has secured. Insurance coverage removes the single biggest barrier between a custom cushion and the people who need it.

Who Needs This Most

The Verro line targets users with complex support needs: windswept posture, severe scoliosis, or pelvic obliquity that standard cushions cannot correct. Seating specialists have long requested a product that sits between generic foam and full custom-molded foam, which can cost thousands of dollars and weigh ten pounds or more.

A 3D printed cushion can hit the middle of that market: personalized fit, lighter weight, and a price insurers will cover.

Competition and Limits

Kalogon is not the only company printing medical seating. Companies in Europe and Asia have dabbled in 3D printed cushions, but Verro is unusual because it is already Medicare-coded in the US market. That regulatory step took years for other products.

The limits today are durability and recycling. Lattice structures can degrade differently than solid foam over years of daily use. Kalogon will need long-term clinical data to prove the cushions hold up. The company also faces questions about end-of-life recycling for printed polymer parts.

The Bigger Picture

If Verro succeeds, it points toward a future where 3D printing moves from novelty to utility in medical seating. The technology is already proven; the challenge was making it manufacturable, reimbursable, and durable. Kalogon is betting that the answer to all three is a lattice printed to your body.