3D-printed cushion transforms Stephanie’s game
Stephanie Altmeier has played wheelchair basketball for over 20 years and recently started para-badminton as well. As an ambulatory wheelchair user with a genetic condition causing chronic pain and hypermobility, she always adapted to the challenges of her sports. But five years ago, her body started pushing back—hip and back pain made training difficult, and her standard foam cushion wasn’t giving her the support she needed.
At RehaCare 2024, Stephanie came across a potential game changer: a 3D-printed cushion in Programmable Foam® from Wolturnus, powered by the Create it REAL print service. She hadn’t expected to find a solution, but as she learned more, she realized this cushion might finally offer the stability and support she had been searching for.
The struggle with seating stability
Wheelchair basketball is a contact sport that requires full-body control. Stephanie’s old cushion wasn’t supporting her properly—her legs lacked stability, and she couldn’t hold her position during fast-paced plays. She tried different approaches and found that a cushion that was too soft caused sinking and discomfort, while a hard one led to pressure pain. On top of that, wheelchair basketball regulations limit cushion height, making standard options even harder to fit her needs.
After years of trying different cushions, she knew exactly what she needed: stability, pain relief, and a cushion that allowed her to perform at her best.
A game-changing solution
Stephanie was already a customer at Wolturnus, a company that supports active wheelchair users with custom-fit equipment. They understand how the right cushion and tailored equipment can significantly impact an athlete’s performance.
At RehaCare 2024, she discovered that Wolturnus had something new lined up—a collaboration with Create it REAL. Together, they introduced 3D-printed cushions in Programmable Foam®, adding custom hardness and softness zones to Wolturnus’ product lineup.
With 3D printing, the Programmable Foam® cushion can be fully customized in one go, making it superior to traditional cushions in terms of pressure relief, ventilation, and hygiene. Plus, its production reduces waste by up to 99%.
Stephanie met Wolturnus at the event and was introduced to the 3D printed cushion, which immediately caught her attention. Could this be the solution she had been searching for? A cushion tailored to the smallest detail—designed to eliminate pain and enhance her performance in a contact sport. Unlike traditional foam cushions, this one promised real customization and support. She took home a sample cushion to test and saw the possibility of finally getting a cushion that could work. Now it was just a matter of working closely with Wolturnus expert Brian Roberts to find the perfect fit.
The final cushion
After months of fine-tuning, the final cushion delivered exactly what she needed. Stephanie and her collaborators made small changes using foam inserts to optimize her positioning while adhering to wheelchair basketball regulations. They accomplished this by testing for the best seating position, designing the cushion, and providing Create it REAL with a dimensioned sketch. Within three months, Stephanie received her new 3D-printed cushion designed specifically for her and had a 3D mesh cover for enhanced airflow. The final cushion provided:
- Leg support – preventing her legs from falling apart.
- A small abductor wedge – keeping her position stable during play.
- An integrated ergo seat – preventing sliding in contact situations.
- Improved hygiene – the cushion doesn’t absorb sweat and is easy to wash.
- Shock absorption – the honeycomb-like structure reduces impact, making movement smoother and pain-free.
Where she once struggled to stay balanced, she now sits with confidence. Where pain used to limit her game, she now plays without hesitation.
Back in the game, pain-free
Stephanie has been using her custom 3D-printed cushion for four months, and the impact on her daily life is undeniable. She can train longer, focus better, and most importantly—play without pain.
Before getting the cushion, pain was a constant limitation. Now, she no longer has to push through pain just to participate. The cushion’s tailored support allows her to engage fully in both wheelchair basketball and para badminton, performing at her best without worrying about discomfort.
The biggest breakthrough? She recently qualified for a para badminton competition—an achievement that wouldn’t have been possible before. With the proper support, she could finally compete at the level she knew she was capable of.
“I’m extremely grateful for the 3D-printed cushion. It changed the way I play both badminton and wheelchair basketball. I’m no longer in pain; I can happily train for hours. My hips and back feel relaxed while playing sports.”
For Stephanie, this cushion wasn’t just about comfort—it was about getting back the joy of playing sports. She no longer worries about pain limiting her time on the court. Instead, she’s focused on pushing her limits and enjoying every moment of the game.
Less sweat, more hygiene
Seating comfort isn’t just about support—it’s also about hygiene and long-term usability. Traditional foam cushions absorb sweat and other liquids, creating a breeding ground for bacteria and odors. Over time, this can make the cushion unpleasant, requiring frequent replacements or extensive cleaning that never fully restores its freshness.
The 3D printed cushion, however, eliminates this issue. Made from a non-absorbent material, it doesn’t soak up moisture, making it more hygienic. Cleaning is effortless—rinse it with a showerhead or toss it in the washing machine. But beyond the easy maintenance, Stephanie also noticed a difference in how much she sweats during use.
Thanks to the cushion’s unique structure, which promotes airflow and breathability. Unlike dense foam, which traps heat and moisture, the honeycomb-like design of the 3D printed cushion allows air to circulate freely, helping to regulate temperature and keep the seating surface dry. This improves comfort and reduces the risk of skin irritation caused by prolonged exposure to sweat and moisture.
For athletes like Stephanie, who spend hours in their wheelchairs, these benefits make a real difference, keeping her focused on the game rather than the discomfort.
"I have to say that I feel like I'm sweating less on the 3D-printed cushion than on my old foam cushion due to the good air circulation. And if I do need to clean it, I can simply wash it."
Pain relief through smart design
Stephanie noticed a difference in comfort from when she used her custom 3D-printed cushion. The change wasn’t just about having a cushion that fit better—it was about how the material and structure worked together to relieve pain.
The 3D-printed cushion distributes weight evenly, adapting to the shape of her body without losing structure. This is due to its honeycomb-like geometry, which provides shock absorption and reduces impact forces when moving or making sudden stops during a game.
“I think the pain reduction is a result of the combination of the relatively soft material and the way it is built up. The cushion for sure also has a shock-absorbing effect, probably due to the honeycomb-like structure.”
The soft yet supportive material combination ensures that Stephanie gets the comfort she needs without sinking too much into the cushion. The result? Less strain on her hips and back, and a better posture while sitting for long hours. This balance between stability and cushioning has made a world of difference—not just for her performance, but for her overall well-being.
More than a cushion
For Stephanie, this was more than just a seating upgrade—a chance to reengage in the game she loves. The 3D-printed cushion didn’t just improve her comfort; it transformed how she played, giving her the stability, control, and endurance she needed to compete at her best.
In wheelchair basketball, every movement counts—quick turns, sudden stops, and physical contact are part of the game. Before, her old cushion left her unstable and unsupported, limiting her ability to react and move effectively. Now, with a cushion tailored to her needs, she sits securely, maintains her position, and moves confidently. The added support allows her to engage without hesitation.
Stephanie’s story highlights the power of custom solutions in adaptive sports. When seating is optimized for the individual, athletes are no longer held back by discomfort or limitations. With the right technology and expertise, seating challenges don’t have to be a barrier—they can be an advantage.
For Stephanie, this cushion isn’t just about sitting. It’s about playing, competing, and pushing her limits—pain-free.
Fact box: Wolturnus Basket – the wheelchair built for performance
Beyond the cushion, Stephanie’s performance is enhanced by her Wolturnus Basket—a wheelchair designed for speed and stability. Stephanie competes in a customized Wolturnus Basket, a high-performance sports wheelchair built for speed, stability, and agility.
- Durability & stability: Made from tempered 7020 aluminum—the strongest weldable aluminum alloy—offering a lightweight yet ultra-stable frame.
- Speed and control: The optimized geometry and low weight help players accelerate and switch directions quickly, giving them a competitive edge.
- Maintenance-free design: The powder-coated frame ensures a hard, durable surface that doesn’t require upkeep.
Tailored to each athlete: Every Wolturnus wheelchair is custom-built to fit the user’s size, strength, and playing position, ensuring the best possible support and performance.
Wolturnus designs products that create opportunities, not limitations, allowing athletes like Stephanie to play at their highest level.