How Robotic Foam Carving Is Transforming Custom Seating in Healthcare and Rehabilitation
Manual foam carving and traditional CNC setups have long been the backbone of custom seating production in both the NHS and private sector. But those methods are increasingly falling short.
With a growing need for speed, flexibility, and precision, robotic foam carving is fast becoming the go-to solution for rehabilitation centres and custom seating manufacturers alike.
Why Rehab and Manufacturing Teams Are Moving Away from Manual and Legacy CNC Systems
Traditional carving methods – manual or legacy 3/5-axis CNC’s – are inefficient, inflexible and still require a lot of manual intervention. Rehab seating teams are spending hours reworking foam blocks, often requiring multiple setups or programmes to carve a single cushion.
Manual carving leads to inconsistencies, 3-axis CNC’s are painful to programme for this application and 5-axis CNC machines struggle to carve the complex profiles, meaning 2-3 programmes are created just to machine the surfaces of one seat or backrest.
Explore the full breakdown of why manual foam carving is holding teams back
Robot Vs CNC: Which system is best for custom seat manufacturers
| Feature / Capability | Manual Carving | 3-Axis CNC | 5-Axis CNC | Robotic Carving System |
|---|---|---|---|---|
| Setup Complexity | Low | Medium | High | Medium |
| Programming Required | None | Multiple tool paths | Multiple tool paths | One toolpath |
| Flexibility of Movement | High (manual) | Low | Moderate | Very High (6–7 Axis) |
| Undercuts/Deep Reach | Manual possible | Limited | Often requires re-positioning | Full access in single setup |
| Repeatability | Low | High | High | High |
| Labour Intensity | Very High | Medium | Low | Low |
| Machining Time (1 cushion) | 3+ hours | 2-3 hours | 1-2 hours | Under 30 minutes |
| Tool Changes | Manual | Semi-automatic | Automatic | Automatic |
| Surface Finish Quality | Operator-dependent | High (if optimised) | Very High | Very High |
| Floor Space Requirement | Low | High | Very High | Compact |
| Material Waste | High | Moderate | Low | Very Low (Optimised toolpaths) |
| Ideal Use Case | One-offs, low budget | Basic carving tasks | High-precision complex tasks | Custom rehab seats, fast prototyping |
From Scan to Seat in a Day - The Digital Workflow
The carving process starts with a postural scan or CAD design. From there:
- CAD is prepared for ENCY CAM software
- Toolpaths are collision-checked and material-optimised
- The robot carves using a rough tool and then auto-switches to a finishing tool (usually completed in 30-40 minutes)
- The final foam seat is ready for test fit the same day
Designers can machine different foam densities for pressure zones and even carve the seat and backrest in one go.
See the full scan-to-seat workflow breakdown
Explore how ENCY optimises every toolpath
Learn how to design effectively for robotic carving
Real-World Proof - NHS and Private Use Cases
- NHS Swansea: Reduced manual hours by 70%, cutting production from days to hours
- Rojac: Carving seat and backrest in a single cycle, with full tool change automation
- LC Seating: Integrated scanning and robotic carving workflow to scale custom seating
- Active Design: Complex patient-specific geometries carved from moulded foam blocks
Foam seats, headrests, armrests and full assemblies - designed, machined, and functional in days, not weeks.
If you’re still hand-cutting or locked into cast tools, there’s a faster route to prototyping and production.
Robotic foam carving isn’t a luxury, it’s the flexible, efficient and clinically ready process custom seat manufacturers and rehab teams need now.