Adaptive Smart Cushion Technology for Enhanced Aircrew Endurance & Readiness
AFWERX · AFWERX TACFI · AFWERX
Award
Description
The Phase II technology solution underlying this TACFI submission involves the development and adaptation of the KALOGON SMART CUSHION for military aviation applications in the B-52 and E-4B platforms under Air Force Global Strike Command (AFGSC). Originally designed for wheelchair users, the Orbiter Smart Cushion uses advanced pneumatic and control systems to dynamically redistribute pressure, enhancing comfort, reducing fatigue, and preventing pressure injuries during long-duration missions. The Phase II SBIR project (Contract #FA864922P0869) focused on adapting Kalogon’s Smart Cushion technology for military aviation applications, specifically for non-ejection seats in the B-52H bomber. The project addressed a critical operational need by mitigating aircrew discomfort, fatigue, and long-term health risks during extended missions. Kalogon’s technology uses machine learning and patent-pending air cell technology to sense and dynamically redistribute pressure in real time, enhancing aircrew comfort, improving blood flow, and reducing the risk of pressure injuries. The development effort followed an iterative design approach, including multiple rounds of prototype development, in-field testing, and human factor evaluations. Testing conducted at Barksdale AFB demonstrated a 700% reduction in reported pain compared to legacy B-52 cushions. Pressure-mapping trials confirmed that Kalogon’s cushion reduced peak pressure levels by up to 51%. Human Subject Research approved by HRPO (711 HPW) further validated these results, showing improved mission readiness and decreased musculoskeletal strain for aircrews. The final V3 prototype integrated advanced pneumatic components, a smaller internal controller, and an extended battery life, removing the need for direct aircraft power. These improvements were guided by Air Force end-user feedback, rapid prototyping (delivering on time and on budget) and validated through environmental, vibration, and vertical impact testing. The successful completion of this effort provides the potential for integration into multiple USAF platforms, including the B-52, E-4B, and ICBM crew stations. This innovation not only supports military aviation but also offers dual-use potential in commercial aerospace and healthcare sectors. As a result of these successful outcomes, AFGSC awarded two additional contracts with 3600 funding: the B-52 Advanced Seat Cushion Contract Modification (FA680024P0002) for expanded system integration and flight testing, and the E-4B Advanced Seat Cushion Contract (FA680024P0020) for cockpit use in the E-4B platform. This Phase II solution directly addresses mission-critical challenges associated with long-duration flights, improving aircrew readiness, operational endurance, and mission success rates. Its successful development and testing have validated its feasibility for broader adoption across additional USAF platforms, positioning it for seamless Phase III transition and fleet-wide implementation.