A system may include an access engine and a foam part generation engine. The access engine may be configured to access a computer-aided design (CAD) seat surface that represents a seat surface of a seat design and access seat parameters for the seat design. The foam part generation engine may be configured to construct a CAD foam part for the seat design based on the CAD seat surface and the seat parameters.

A pocketed resilient unit (130), such as for a mattress core, comprises integral pocketed resilient elements (110) arranged in clusters (240), wherein each integral pocketed resilient element in a cluster is attached to at least one other integral pocketed resilient element, and wherein the clusters define interstices (250), in at least some of which are located independent resilient elements (260).

A pocketed resilient unit (130), such as for a mattress core, comprises integral pocketed resilient elements (110) arranged in clusters (240), wherein each integral pocketed resilient element in a cluster is attached to at least one other integral pocketed resilient element, and wherein the clusters define interstices (250), in at least some of which are located independent resilient elements (260).

A process is disclosed for making seats, for example bicycle seats, which include at least one shell, at least one covering sheet or covering, and at least one gel padding element, which adheres to at least one intermediate adhesion sheet made of a material having micro holes or holes or a woven fabric, which in turn adheres to a surface of the at least one covering. Equipment configured to implement such process is also disclosed.

A process is disclosed for making seats, for example bicycle seats, which include at least one shell, at least one covering sheet or covering, and at least one gel padding element, which adheres to at least one intermediate adhesion sheet made of a material having micro holes or holes or a woven fabric, which in turn adheres to a surface of the at least one covering. Equipment configured to implement such process is also disclosed.

A method for fabricating custom seat bolsters includes receiving a first image of a user in a first pose and a second image of the user in a second pose. The method further includes generating a 3D body scan model based on at least the first image of the user and the second image of the user. The method further includes determining a design for a set of seat bolsters for the user based on the 3D body scan model. The method further includes providing the set of seat bolsters for the user based on the determined design.

A method for fabricating custom seat bolsters includes receiving a first image of a user in a first pose and a second image of the user in a second pose. The method further includes generating a 3D body scan model based on at least the first image of the user and the second image of the user. The method further includes determining a design for a set of seat bolsters for the user based on the 3D body scan model. The method further includes providing the set of seat bolsters for the user based on the determined design.

In order to manufacture an innerspring unit comprising pocketed springs and having an increased stability at its edge regions, in a first step, an innerspring main body comprising a plurality of first strings of pocketed springs is provided. In a subsequent second step, at least one second string of pocketed springs is attached to a lateral surface of the innerspring main body, so that the at least one second string of pocketed springs extends in a longitudinal direction of the innerspring main body. The springs of the at least one second string of pocketed springs have a spring characteristic or a spring geometry different from the springs of the plurality of first strings of the innerspring main body. The at least one second string of pocketed springs forms together with the innerspring main body the innerspring unit.

In order to manufacture an innerspring unit comprising pocketed springs and having an increased stability at its edge regions, in a first step, an innerspring main body comprising a plurality of first strings of pocketed springs is provided. In a subsequent second step, at least one second string of pocketed springs is attached to a lateral surface of the innerspring main body, so that the at least one second string of pocketed springs extends in a longitudinal direction of the innerspring main body. The springs of the at least one second string of pocketed springs have a spring characteristic or a spring geometry different from the springs of the plurality of first strings of the innerspring main body. The at least one second string of pocketed springs forms together with the innerspring main body the innerspring unit.

A mattress or mattress topper includes a cushioning element having an elastomeric material forming intersecting buckling walls that define hollow columns, and a knitted fabric disposed over the cushioning element and configured to move independently of the buckling walls. The elastomeric material includes an elastomeric polymer and a plasticizer. The knitted fabric includes a first layer of stretchable material; a second layer of stretchable material; and a layer of stretchable fill material between the first layer of stretchable material and the second layer of stretchable material. The first layer of stretchable material is knitted together with the second layer of stretchable material as a unitary sheet of fabric including the layer of stretchable fill material. A method of forming a mattress or mattress topper includes disposing a knitted fabric over a cushioning element comprising intersecting buckling walls and configuring the knitted fabric to move independently of the buckling walls.