ErgoLux

Body cushions that make cramped working positions comfortable. Labor workers from every industry find themselves in uncomfortable working situations. Ergolux Body Pads protect them, so they can get the job done. 

 
 

The Problem

Typical body mats or kneeling pads are too thin, small, and expensive. Working in low positions, crouching, and kneeling are the leading causes of work fatigue. Working in comfortable positions means less stress, strain, soreness, fewer accidents, fewer sick days, and happier employees.  

 
 

Kneeling Hurts

It hurts more than your knees. Feet are strained, which is why thin kneeling pads don’t solve all of the problems. Thicker kneeling cushions not only protect the knee but also support the feet.

 

Knee Point Pressure 

Kneeling on hard surfaces for long periods can lead to knee bursitis, causing pain and limiting joint mobility. Using thick kneeling pads avoids point pressure on the knee.

Ankle Overextension 

Bodyweight, while kneeling, is primarily over the feet. Using the cushion elevates the ankles eliminating overextension of the Achilles tendon. 

toe strain

Toes shouldn’t bend this way for long. Weight on the toes in this cramped position is not healthy and will lead to joint damage. Resting your shins on the cushion supports your bodyweight, which alleviates toe strain.

 

Solution

A series of thick cushions of different shapes and sizes and reasonably priced. 

Body cushions are either three or six inches thick to provide maximum protection. They vary in size and shape for use in a wide range of applications. The ten-piece kit stacks nicely into a 20”x20”x20” storage bag. 

To keep production costs low, I found excess materials that could be up-cycled: packaging foam, extra fabric, leather, thread, velcro, and seat belts. By using these materials, the only production cost is labor. 

 

What’s included?

1st Generation Kit:

  • One 6” Large

  • One 6” Medium

  • Two 6” Small

  • Two 3” Medium

  • Four 3” Small

  • One Storage Bag

2nd Generation Kit:

  • One 6” Large

  • One 6” Medium

  • Two 6” Small

  • One 3” Large

  • One Storage Bag

All cushions can also be ordered individually.

3 x 5 x 10

3” Small

3 x 5 x 20

3“ Medium

3 x 12 x 15

3” Large

6 x 10 x 15

6" Small

6 x 15 x 20

6” Medium

6 x 20 x 20

6” Large

 

Prototyping, easy assembly, quick to sew

Each cushion consists of two panels. The top and bottom panels are sewn together with one seam. This method keeps production time low.

Below, I follow the path of the single seam around a cushion.

 
 

fast-cut templates

Cutting the top and bottom panels from rolls of fabric can be time-consuming. Creating a manufacturing process using cutting templates speeds things up. After drafting patterns for each cushion, I created CAD files and had aluminum templates made with a CNC water jet. I chose aluminum because the soft metal does not dull or damage rotary cutter blades.