Op maat van jouw lichaam – De zoektocht naar geautomatiseerd maatwerk in ergonomische bureaustoelen
De helft van de Belgische werknemers brengt meer dan vijf uur per dag zittend door; een kwart van hen zit zelfs meer dan zeven uur. En hoewel de meeste bureaustoelen verstelbaar zijn in de zithoogte, armleuning en lendensteun blijken rug- en nekklachten opvallend vaak voor te komen. Verrassend, of toch niet? Hoe goed je zo’n stoel ook afstelt, het blijft in essentie een standaardproduct. En daar wringt het. Want geen twee lichamen zijn hetzelfde.
“Waarom zou iedereen op dezelfde stoel moeten zitten?”
Die vraag vormde het vertrekpunt van deze masterproef. Als een ergonomische bureaustoel niet langer als standaardproduct wordt ontworpen, maar als massapersonaliseerbaar product, kan het ontwerp veel beter worden afgestemd op de ergonomische noden van elke gebruiker.
De Brugse start-up Nozzle maakt vandaag al ergonomische bureaustoelen op maat, die zorgvuldig ontworpen zijn door een ergotherapeut met ervaring in ergonomie en rug revalidatie en een ingenieur gespecialiseerd in 3D-printtechnologie. Hoewel het resultaat prima is, vergt deze aanpak gemiddeld ongeveer anderhalf uur ontwerpwerk per stoel.
Dat moet sneller kunnen. Het concept achter deze masterproef is dan ook eenvoudig: geef de computer een gedetailleerde 3D-scan van iemands lichaam en laat hem vervolgens een bureaustoel ontwerpen die specifiek bij die persoon past. Zo’n 3D-scan is opgebouwd uit duizenden meetpunten die met elkaar verbonden zijn. Vervolgens maakt het computerprogramma gebruik van vooraf gedefinieerde patronen om deze puntcoördinaten betekenis te geven en te koppelen aan specifieke lichaamsonderdelen, bijvoorbeeld de knieën, heupen en wervelkolom. De computer leert als het ware wat de afmetingen en de lichaamshouding van de persoon is. Deze informatie vormt vervolgens de basis voor het latere stoelontwerp.
De volgende vraag is een stuk moeilijker: hoe weet de computer bij welk lichaam welke stoel past?
Daarvoor werden geometrische ontwerpregels ontwikkeld die de computer kan toepassen. Die regels leggen verbanden tussen de afmetingen van het lichaam, de lichaamshouding en de vorm van de stoel. Op basis van deze regels zal dan een complex programma de stoelgeometrie genereren. Zo kan de hoogte van de heup in zittende houding bijvoorbeeld gebruikt worden om de ideale zithoogte te bepalen. Op dezelfde manier kunnen andere lichaamsmaten worden vertaald naar de afmetingen van de zitting, armleuningen en rugleuning.
Daarbij speelt parametrisch ontwerpen een belangrijke rol. In plaats van voor elke persoon helemaal opnieuw een stoel te tekenen, wordt één slim digitaal model gemaakt. Dat model bevat verschillende variabelen die automatisch kunnen veranderen. Heeft iemand bijvoorbeeld langere benen? Dan past de computer de zithoogte aan. Verandert een andere lichaamsmaat, dan verandert de stoelgeometrie mee.
Eén digitaal model kan zo een hele reeks unieke stoelen opleveren, steeds getuned naar het lichaam van elke individuele gebruiker.
De rugleuning: de grootste uitdaging
Een goede rugleuning moet niet alleen de juiste afmetingen hebben, maar ook aansluiten bij de natuurlijke kromming van iemands lichaam.
Om dat mogelijk te maken, werd een statistisch model ontwikkeld op basis van verschillende lichaamsscans. Een ervaren ergotherapeut bepaalde voor elke scan welke vorm de rugleuning moest krijgen. Vervolgens leerde het model verbanden leggen tussen de houding van het lichaam en de gewenste vorm van de rugleuning. Op die manier leert de computer van menselijke expertise.
Van de theorie naar de praktijk
Doorheen het masterproeftraject werd een methode ontwikkeld die op basis van een 3D scan van een persoon, iemand toelaat om binnen de 10 minuten een correct ergonomische bureaustoel te genereren. De methode werd toegepast op 12 verschillende kwalitatieve lichaamsscans gecombineerd met meer dan 40 verschillende patronen voor de rugleuning en in alle gevallen leverde de computer een passend stoelmodel op. Zolang de lichaamsscans een correcte geometrie bevatten maakt het programma geen fouten.
Het programma analyseert de 3D-scan, bepaalt de relevante lichaamsmaten en genereert vervolgens automatisch een stoelmodel.
Ook wordt het model voorbereid voor 3D-printing, zodat het ontwerp niet alleen digitaal mooi is, maar ook daadwerkelijk geproduceerd kan worden en voldoende stevig is.
En het bleef niet bij een digitaal ontwerp. Met de ontwikkelde methode werd een volledig gepersonaliseerde bureaustoel op ware grootte geproduceerd met behulp de 3D-printtechnologie bij Nozzle. De stoel werd vervolgens getest op meerdere ergonomische aspecten, automatiseerbaarheid en reproduceerbaarheid. De gelukkige gebruiker kon de stoel vervolgens zelf uitproberen.
De computer als ontwerp assistent
De computer kan duizenden berekeningen uitvoeren en telkens opnieuw geometrische aanpassingen maken, in minuten. Daardoor kan een proces dat vandaag veel handmatig werk vraagt, grotendeels worden geautomatiseerd.
Maar de computer neemt het ontwerp niet volledig over. Menselijke expertise blijft belangrijk bij onder meer kwaliteitscontrole, bijsturing in bijzondere situaties en context
De grote verandering zit dus niet in een computer die de mens vervangt, maar in een computer die de mens extra tools biedt.
Het onderzoek toont aan dat individueel maatwerk perfect combineerbaar is met een doorgedreven automatisatie waardoor het ontwerp en productieproces efficiënter en sneller kan plaatsvinden.
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