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Aldermans News
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(0)1752 201200
CareFlex- SmartSeatPro
The requirement
CareFlex designs and manufactures specialist chairs for children and adults with limited mobility, improving their quality of life by preventing complications such as muscle wastage and pressure sores. Their chairs are widely used in nursing homes, specialist hospital wards, intensive therapy units, and domestic settings to provide essential postural support and pressure relief.
In 2013, CareFlex began developing its latest model, the SmartSeatPro, a highly adjustable chair designed for individuals with severe mobility challenges. This chair offers multiple adjustment options, including seat depth and width, variable recline angles, and a unique nine-section back system. It is particularly beneficial for people with conditions such as Multiple Sclerosis, Muscular Dystrophy, Motor Neurone Disease, Cerebral Palsy, and spinal cord injuries.
To bring the SmartSeatPro to market, CareFlex required precisely manufactured metal components, including folded brackets, welded tubes, and laser-cut parts, all of which needed to be powder-coated for durability. With a 20-year working relationship with Aldermans, CareFlex naturally turned to them for their technical expertise, reliability, and ability to meet tight production deadlines.
The solution
CareFlex collaborated with Aldermans’ Technical Engineer & Estimator, Paul Weeks, to ensure the components met the high tolerance requirements of the SmartSeatPro. Given the tight three-week deadline for the first batch of ten units, Aldermans had to rapidly prototype, refine, and scale production while maintaifning exceptional quality.
The manufacturing process began with laser cutting each part using Aldermans’ Amada C1 punch-laser combination machine, which ensures superb precision. The cut profiles were then transferred to the fabrication shop, where they were folded using press brakes and power presses. With Aldermans’ in-house capability to bend and form metal sheets and coils between 0.6mm and 6mm, as well as tubes and bars between 5mm and 50mm, the team could meet the exact specifications required.
To ensure consistency, custom-built welding jigs were used, allowing for repeatable production while maintaining tight tolerances. Once welded, the parts were powder-coated to enhance durability and withstand frequent daily adjustments, before undergoing rigorous quality testing.
The outcome
Aldermans successfully met the initial deadline, delivering the first batch of ten sets within three weeks, ensuring that CareFlex could proceed with its product launch. With the first units approved, full production of the remaining 90 sets commenced, guaranteeing a consistent and repeatable manufacturing process.
To streamline logistics, Aldermans implemented a call-off inventory management system for CareFlex. This system allows CareFlex to store components at Aldermans’ facility, enabling quick supply whenever needed. With real-time stock monitoring, CareFlex can make informed ordering decisions, ensuring smooth production flow and preventing delays.
The SmartSeatPro was officially launched in 2015, receiving high-profile recognition for its revolutionary design. It continues to improve the lives of individuals with complex care needs, offering superior postural support, pressure relief, and comfort.
Aldermans is proud to have contributed to this innovative project and looks forward to supporting CareFlex with future developments, reinforcing their long-standing partnership in delivering high-quality, precision-engineered seating solutions.
Client testimonial
‘We consider Aldermans to be a reliable supplier. No enquiry is too much trouble. They are competitively priced and are able to flex lead-times to aid project development. Generally all products we receive are exactly what we expect, delivered on-time. When we have a problem, it is dealt with quickly, professionally and with minimal fuss.’
-Chris Northcott , Senior Design Engineer, CareFlex
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We are one of the South West’s leading metal fabricators. With 50 years’ experience, we are specialists in sheet metal fabrication and custom metal parts.
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