journal article·2025-09-18Open access

Finite Element Modeling of Human–Seat Interaction and the Integration of 3D-Printed Foam in Enhancing Sitting Comfort: A Systematic Review

Minh Tien Nguyen, Akinari Hirao

Applied Sciences· Volume 15· Issue 18

Abstract

The aim of this systematic review is to summarize studies that apply the finite element method (FEM) to simulate human–seat interaction, while also evaluating the role of 3D-printed foam materials in enhancing sitting comfort. These studies employ a variety of human body models, ranging from basic to fully detailed representations including muscles, bones, and joints. Although simulation methods have continuously evolved, contact pressure remains the most commonly used evaluation metric. Additionally, 3D printing is a technology that enables the customization of material structures and has gained increasing attention due to its wide applicability in engineering. Recognizing the potential of 3D-printed foams in improving pressure distribution, this review systematically analyzed 42 full-text papers. The findings reveal a significant gap in the integration of 3D printing technology into foam design using FEM for the human–seat interface. This identifies a promising direction for future research.
Source: crossref · Quality: baseline

Research context

OpenAlex topics: Ergonomics and Musculoskeletal Disorders

SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.

Affiliations

College of Design Engineering, Shibaura Institute of Technology, Tokyo 135-8548, Japan

References (70)

Show source-provided references
1. Is questionnaire-based sitting time inaccurate and can it be improved? A cross-sectional investigation using accelerometer-based sitting time10.1136/bmjopen-2016-013251 ↗
2. Amount of time spent in sedentary behaviors in the United States, 2003–200410.1093/aje/kwm390 ↗
3. Too much sitting—A health hazard10.1016/j.diabres.2012.05.020 ↗
4. Is sitting invisible? Exploring how people mentally represent sitting10.1186/s12966-019-0851-0 ↗
5. Kyphosed seated postures: Extending concepts of postural health beyond the office10.1007/s10926-008-9123-6 ↗
6. Markova, V., Markov, M., Petrova, Z., and Filkova, S. (2024). Assessing the impact of prolonged sitting and poor posture on lower back pain: A photogrammetric and machine learning approach. Computers, 13.10.3390/computers13090231 ↗
7. Assessment of aircraft passengers’ comfort with varying seat pitch
8. Sitting comfort in an aircraft seat with different seat inclination angles10.1016/j.ergon.2023.103470 ↗
9. Articulation at shoulder level—A pilot experimental study on car seat comfort10.1016/j.apergo.2011.03.003 ↗
10. Comfortable automotive seat design and big data analytics: A study in thigh support10.1016/j.apergo.2018.08.020 ↗
11. Effects of differences in office chair controls, seat and backrest angle design in relation to tasks10.1016/j.apergo.2008.11.011 ↗
12. Effect of two dynamic seat cushions on postural shift, trunk muscle activation and spinal discomfort in office workers10.1016/j.apergo.2024.104337 ↗
13. A fuzzy logic controller to seat comfort correction for manually propelled wheelchair—A case study10.1016/j.ifacol.2016.12.010 ↗
14. Power seat function usage and wheelchair discomfort for power wheelchair users10.1080/10790268.2016.1192360 ↗
15. Effect of the thickness of polyurethane foams at the seat pan and the backrest on fore-and-aft in-line and vertical cross-axis seat transmissibility when sitting with various contact conditions of backrest during fore-and-aft vibration10.1016/j.apergo.2021.103354 ↗
16. Design and modeling using finite element analysis for the sitting posture of computer users based on ergonomic perspective10.1007/s12008-023-01383-9 ↗
17. The contribution of seat components to seat hardness and the interface between human occupant and a driver seat10.1504/IJHFMS.2012.051570 ↗
18. Liu, S., Beillas, P., Ding, L., and Wang, X. (2023). PIPER adult comfort: An open-source full body human body model for seating comfort assessment and its validation under static loading conditions. Front. Bioeng. Biotechnol., 11.10.3389/fbioe.2023.1170768 ↗
19. Virtual optimisation of car passenger seats: Simulation of static and dynamic effects on drivers’ seating comfort10.1016/j.ergon.2007.08.016 ↗
20. Liu, S., Beillas, P., Ding, L., and Wang, X. (2024). Effects of loading processes on contact forces when simulating static seating with a finite element human body model. Comput. Methods Biomech. Biomed. Eng., 1–8.10.1080/10255842.2024.2410225 ↗
21. Hogeveen, T., Ballemans, M., Strijker, A., Ammerlaan, B., and Vink, P. (2023, January 6–7). Towards an environment friendly comfortable aircraft seat. Proceedings of the Fourth International Comfort Congress, Amberg, Germany.
22. 3D printed sports shoe midsoles: Enhancing comfort and performance through finite element analysis of negative Poisson’s ratio structures10.1016/j.matdes.2024.113292 ↗
23. 3D-printed motorcycle seats: Replicating polymer foam performance for rapid prototyping and rider comfort
24. Impact of Anthropometric Parameters on Pressure Variables for Determining Comfort and Safety of Automotive Seat: A Systematic Review
25. Citation: Alawneh, O., Zhong, X., Faieghi, R., and Xi, F. (2022). Finite Element Methods for Modeling the Pressure Distribution in Human Body–Seat Interactions: A Systematic Review. Appl. Sci., 12.10.3390/app12126160 ↗
26. Silberstein, J., and Sun, Z. (2024). Advances and Applications of Three-Dimensional-Printed Patient-Specific Chest Phantoms in Radiology: A Systematic Review. Appl. Sci., 14.10.3390/app14135467 ↗
27. Mikołajewska, E., Mikołajewski, D., Mikołajczyk, T., and Paczkowski, T. (2025). A Breakthrough in Producing Personalized Solutions for Rehabilitation and Physiotherapy Thanks to the Introduction of AI to Additive Manufacturing. Appl. Sci., 15.10.3390/app15042219 ↗
28. The PRISMA 2020 statement: An updated guideline for reporting systematic reviews10.1136/bmj.n71 ↗
29. Rayyan-a web and mobile app for systematic reviews10.1186/s13643-016-0384-4 ↗
30. Zhang, T., Ren, J., and Qi, S. (2023). Modeling Method and Effect of Seat Cover on the Simulation of Interface Pressure, SAE Technical Paper. 2023-01-0910.10.4271/2023-01-0910 ↗
31. Development and validation of a high anatomical fidelity FE model for the buttock and thigh of a seated individual10.1007/s10439-016-1560-3 ↗
32. Development of a Human-Seat Cushion Finite Element Model for Sitting Comfort Analysis
33. Li, S., Yin, M., Gao, L., Qi, S., and Wang, J. (2016). Finite Element Prediction of Sub-dermal Tissue Stresses of the Buttocks during Wheelchair Propulsion. J. Mech. Med. Biol., 16.10.1142/S0219519416500585 ↗
34. Ren, J., Du, X., Liu, T., Liu, H., Hua, M., and Liu, Q. (2017). An Integrated Method for Evaluation of Seat Comfort Based on Virtual Simulation of the Interface Pressures of Driver with Different Body Sizes, SAE Technical Paper. 2017-01-0406.10.4271/2017-01-0406 ↗
35. Research on the Simulation of Human-Seat Interface Pressure with Consideration of the Effect of Seat Cover
36. Development and evaluation of a new methodology for the fast generation of patient-specific Finite Element models of the buttock for sitting-acquired deep tissue injury prevention10.1016/j.jbiomech.2018.08.001 ↗
37. A design method for contact contour based on the distribution of target contact pressure10.1007/s10999-023-09674-5 ↗
38. Modeling of human model for static pressure distribution prediction10.1016/j.ergon.2015.09.017 ↗
39. Effect of whole-body vibration and sitting configurations on lumbar spinal loads of vehicle occupants10.1016/j.compbiomed.2019.02.019 ↗
40. A design for seat cushion and back-supporter using finite element analysis for preventing decubitus ulcer10.1299/jbse.16-00586 ↗
41. Effect of lumbar support on seating comfort predicted by a whole human body-seat model10.1016/j.ergon.2016.03.004 ↗
42. Analysis of seat cushion comfort by employing a finite element buttock model as a supplement to pressure measurement10.1016/j.ergon.2021.103211 ↗
43. Huang, S., Sun, D., Zhang, L., Zhou, J., and and Wang, Z. (2022). Comfort Assessment and Optimization Based on FE Simulation for High-Speed Train Seats: Comparison with Different Design Parameters. Sustainability, 14.10.3390/su142215185 ↗
44. Biomechanical human models for seating discomfort assessment10.1016/B978-0-12-816713-7.00049-0 ↗
45. Cheng, L., Wen, H., Ni, X., Zhuang, C., Zhang, W., and and Huang, H. (2023). Optimization Study on the Comfort of Human-Seat Coupling System in the Cab of Construction Machinery. Machines, 11.10.3390/machines11010030 ↗
46. Lazarov, N., Siefert, A., and Fressmann, D. (2015, January 15–17). The CASIMIR Model for Simulation in Seating Comfort Applications. Proceedings of the 10th European LS-DYNA Conference 2015, Würzburg, Germany.
47. Siefert, A. (2016). Occupant Comfort—A Mixture of Joint Angles, Seat Pressure and Tissue Loads, SAE Technical Paper. 2016-01-1438.10.4271/2016-01-1438 ↗
48. Alam, D.N., and Chennubhotla, V. (2019). Use of CAE Tool to Evaluate the Body Pressure Distribution Plot on Automotive Seating, SAE. SAE Technical Paper.10.4271/2019-01-0402 ↗
49. Develop Best Practices for Correlating Body Pressure Distribution Test to Simulation10.4271/2022-01-0809 ↗
50. Correlating Body Pressure Distribution Test to Simulation
51. Kamaraju, P., and Ro, H. (2024). Application of the Design of Experiments to Study the Sensitivity and Contribution of a Seat Back Bladder Bolster on Occupant Lateral Support Performance, SAE Technical Paper. 2024-26-0303.10.4271/2024-26-0303 ↗
52. Hans, T., Pan-Zagorski, W., Shah, T., and Buchner, T. (2023, January 6–7). Virtual Analysis of Dynamic Seat Comfort. Proceedings of the Fourth International Comfort Congress, Amberg, Germany.
53. Liu, S., Beillas, P., Ding, L., and Wang, X. (2020). Morphing an Existing Open Source Human Body Model into a Personalized Model for Seating Discomfort Investigation, SAE. SAE Technical Paper.10.4271/2020-01-0874 ↗
54. Bui, H.T., Lestriez, P., Pradon, D., Debray, K., Abdi, E., and Taiar, R. (2018). Biomechanical Modelling of Medical Seat Cushion and Human Buttock-thigh Tissue to Prevent Pressure Ulcers. Russ. J. Biomechanics.
55. The Evaluation of the Interaction Between Human Buttocks Thighs and Wheelchair Seat Cushion to Prevent Pressure Ulcers Using Finite Element Analysis10.1007/978-3-030-02053-8_137 ↗
56. Identifying Factors That Influence Pressure Ulcers by Numerical Simulation and Experimentation Methods10.3991/ijoe.v16i11.13817 ↗
57. Robust evolutionary shape optimization for ergonomic excellence based on contact pressure distribution10.1080/10255842.2020.1774751 ↗
58. Tran, X.-T., Nguyen, V.-H., and Nguyen, D.-T. (2025). Finite Element Analysis of the Contact Pressure for Human–Seat Interaction with an Inserted Pneumatic Spring. Appl. Sci., 15.10.3390/app15052687 ↗
59. Chen, L., Song, J., Niu, X., Sun, C., and Qiu, Y. (2022). Experiment and Simulation Study on Vibration Transmission Characteristics of Seat-Occupant Coupling System, SAE. SAE Technical Paper.10.4271/2022-01-5095 ↗
60. Modeling of vehicle seat in lumped network model for ride comfort simulation10.1007/s12206-020-1222-0 ↗
61. Bermamet, H., Syed, S., and Amer, S. (2022, January 26–28). Investigating the Effect of Seat Features and Cushion Material on Seat Comfort using Finite Element Analysis. Proceedings of the 5th European International Conference on Industrial Engineering and Operations Management, Rome, Italy.10.46254/EU05.20220315 ↗
62. An Overview on 3D Printing Technology: Technological, Materials, and Applications
63. Customized Design for Ergonomic Products via Additive Manufacturing Considering Joint Biomechanics
64. Zhang, J., Lu, S., Lin, Y., Wang, Y., Yi, X., and Fang, W. (2024). Pressure-Reducing Design of 3D-Printed Diabetic Shoe Midsole Utilizing Auxetic Lattice Structure. Appl. Sci., 14.10.3390/app14125291 ↗
65. Zhang, J., Lu, S., Yang, Y., Liu, Y., Guo, Y., and Wang, H. (2024). Efficacy of auxetic lattice structured shoe sole in advancing footwear comfort—From the perspective of plantar pressure and contact area. Front. Public Health, 12.10.3389/fpubh.2024.1412518 ↗
66. Mechanical behaviour of flexible 3D printed gyroid structures as a tuneable replacement for soft padding foam
67. Design and characterization of 3D-printed TPU-based lattice structures. Application to methodology for the design of personalized therapeutic products10.1108/RPJ-08-2023-0287 ↗
68. Optimization and biodynamic modelling of a 3D-printed honeycomb cushion and double-diamond seating suspension system for vibration isolation10.1177/10775463231210580 ↗
69. Prediction of mechanical behavior of 3D bioprinted tissue-engineered scaffolds using finite element method (FEM) analysis
70. New quadratic and cubic polynomial enrichments of the Crouzeix–Raviart finite element10.1016/j.camwa.2024.06.019 ↗