Kalogon launches Verro, a 3D printed wheelchair cushion that fits you

What Verro actually is

Kalogon calls Verro a custom seating cushion, but the interesting part is how it gets made. Every cushion starts with a capture of the user's body. A clinician can take a 3D scan from a physical mold of the person in their seated position, or just type measurements into Kalogon's Launch Pad configurator. Either way, the order ships within 14 days.

The inside is a 3D printed elastomer lattice. The trick is that the firmness varies across the surface. One printed part can feel soft in one spot and firmer a few centimeters away, because the internal structure changes locally.

Why zone by zone stiffness matters

Wheelchair users with complex seating needs rarely fit a one shape fits all cushion. Pressure that builds in the wrong place causes pain and skin breakdown. Tuning stiffness per zone lets a single cushion do what used to take layers of off the shelf pads.

Kalogon is not the first to play this game. Mahdi Naim Studio's AERIS bicycle saddle uses three lattice density zones to balance support and relief for cyclists. Osprey patented a similar zoned approach for a 3D printed lumbar pad. Kalogon is applying the same engineering idea to a harder problem: keeping a person comfortable and protected through a full day in a chair.

Built for the real world, not just the demo

Verro carries the E2609 Medicare code, which matters because it puts the cushion inside a reimbursement pathway clinicians already use. Kalogon makes every unit at its own facility in Melbourne, Florida. The company started in 2019 and spent its early years on smart cushions with sensors and adaptive surfaces before moving into custom 3D printed seating.

"Every client is different, and seating specialists need options that reflect that," said Kelly Waugh, an advisor to Kalogon. "That flexibility will allow Kalogon to serve a much wider population of people with complex seating needs than before."

The bigger signal

Mass customization gets talked about constantly in 3D printing, but most of it lands in prototypes and one off trinkets. A wheelchair cushion is different. It is a regulated medical product, fitted to one body, made in small batches, and paid for through insurance. That is exactly the kind of application the industry has promised for years. Verro suggests the promise is finally showing up where it counts.