Inside the MAPS Carved Foam Workflow From Assessment to Final Fit

For individuals whose postural needs cannot be accommodated effectively with modular or orthogonal seating, carved foam offers a clinically driven method to provide stable, intimate contact and support. The MAPS (Moulded Approach to Postural Seating) Carved Foam process integrates clinical assessment, precision scanning and controlled manufacture, enabling seating that reflects individual contours and functional needs.

Assessment and decision process

MAPS begins with a detailed clinical postural assessment, typically conducted in collaboration with local therapy teams. This assessment establishes range of movement, postural deformity, fixed versus correctable elements, and how the pelvis, trunk and limbs interact in sitting. When modular seating cannot achieve the required contact and stability, a carved foam approach is considered. This decision is based on postural presentation rather than preference.

Once carved foam is indicated, the assessment continues with a thorough plinth evaluation to confirm alignment goals and to identify key points of support and pressure risk.

A bead-filled casting bag is then used to capture the individual’s shape. Once the person is positioned according to clinical intent, the air is removed so the beads lock into place, holding the pelvis and trunk in the required alignment. This ensures the cast reflects not only body form, but also the intended functional alignment.

Digital capture and manufacture

The impression is scanned with a 3D camera and translated into digital data. This data is supported by the clinical seating engineers’ input, specifying areas requiring containment, pressure redistribution or differential foam densities. Using state of the art computer controlled six-axis milling robot, the block of foam is carved to match the scanned contours with precision. This computer-guided workflow ensures repeatability and accuracy across the seating surface.

The carved foam is hand-finished, fitted to an appropriate shell and covered with tailored upholstery. Carefully selected accessories such as headrests, foot plates. Harnesses and pelvic supports are incorporated as required. The final assembly is configured to interface securely with the chosen wheelbase.

Final fitting

In the clinic, adjustments are made to ensure contours support the intended posture. By maintaining consistent contact and alignment, the seat supports functional posture across environments, whether at home, in education settings or during therapy.

This structured workflow emphasises collaboration, clinical reasoning and engineering precision, all directed at producing seating that supports safety, comfort and functional engagement for people with the most complex postural needs.