Ultra Air Mesh Technology

In today’s demanding work culture, many office workers spend over 10 hours a day seated in the same chair, often in poorly ventilated spaces or under harsh indoor conditions. Prolonged sitting in an unsuitable chair is more than just uncomfortable—it starts with sweaty backs, sticky thighs, and constant fidgeting, which may seem minor at first but can lead to chronic lower back pain, poor posture, reduced thigh circulation, and even skin irritation over time. Beyond physical strain, these issues sap energy and focus, leaving us restless, fatigued, and less productive.

To address these challenges, we partnered with German experts renowned for their expertise in precision engineering and textile innovation. Together, we developed Ultra Air Mesh—a material featuring multiple layers of woven microcavities and special coatings. Inspired by technologies used in sportswear and mattress covers, it is designed to optimize airflow, comfort, and thermal regulation. The result is a durable and highly functional solution that enhances ventilation and ergonomic support, improving both comfort and productivity during long workdays.

The secret lies in its multi-dimensional design. Multiple micro-mesh layers are engineered with a mix of microstructured surfaces and overlapping layers to improve airflow and manage moisture. The microstructured surfaces create a textured design that increases the open area, enabling more air to pass through. This structure ensures air flows smoothly across the surface, making it easier to release heat.

Building on this, the overlapping layers add microcavities—tiny gaps or channels formed naturally when stacked and interwoven. These microcavities create additional pathways for air and moisture to move through, further improving airflow and ventilation. The design leverages Bernoulli’s Principle, where air speeds up as it flows through narrow spaces, enhancing convective heat transfer and efficiently carrying heat away.

Where:

Result: As air flows through the narrow microcavities, its velocity () increases while pressure () decreases. This pressure drop pulls more air through the mesh.

When combined, the microstructured surfaces and multi-layered mesh work together to form a dynamic airflow system. The textured surface helps air move easily, while the layers boost this effect by guiding airflow and pulling moisture through the mesh using capillary action, similar to how a sponge wicks water. This synergy not only promotes faster moisture evaporation but also ensures heat is distributed evenly and removed efficiently.

The result is an advanced material—Ultra Air Mesh—that delivers superior airflow, better heat control, and enhanced comfort for prolonged sitting.

Single-layer meshes use tightly packed threads to maintain tension and support weight. According to principles of tensile strength, this dense structure evenly distributes the load across the surface, preventing deformation under pressure and ensuring the mesh stays functional.

However, this density reduces the open area. This means only a small percentage of the surface allows air to pass through, making it harder for heat to escape. Without additional layers or pathways to compensate, the structure traps heat, reducing cooling efficiency.

Our engineers realized the need to improve cooling efficiency while maintaining the mesh strength. To overcome the limit of single-layered mesh, we developed a multi-layered design with larger mesh openings (1,000µm).

This design layers multiple sheets of mesh, interwoven to form a network of tiny channels (microcavities), significantly increasing airflow and moisture movement without compromising the structure's strength. The overlapping layers even surpass the strength and durability of single-layer design—distributing force and localized stress more effectively by spreading the load across multiple points, ensuring better support underweight.

To further enhance performance, we optimized the material composition with 72% polyester and 28% polyamide. This specific ratio takes advantage of polyester's high tensile strength while incorporating polyamide for its flexibility and resistance to wear and tear. Together, they create a balanced structure that provides both strong support and prolonged comfort.

Enhanced Airflow and Comfort: Ultra Air Mesh, developed with German experts, traps more air than regular polyester mesh. Its breathable, towel-like fabric keeps users cool and comfortable, even in warm conditions, providing better airflow and heat control.

Pressure Mapping and User Feedback: Pressure mapping showed Ultra Air Mesh effectively redistributes pressure on key areas like the lumbar and thighs. The traction pattern adjusts to every posture, providing active support during work or relaxation. User feedback highlighted how naturally the mesh adjusts to their seating habits.

Sustainability and Durability: The material composition (72% polyester and 28% polyamide) ensures durability, withstanding daily wear and maintaining structural integrity over time. Its compatibility with the metal frame ensures long-lasting comfort and support, reducing waste and promoting sustainability.

The Ultra Air Mesh introduces a groundbreaking approach to ergonomic seating by focusing on enhanced airflow, pressure redistribution, and long-term durability. Designed with multi-layered engineering and material composition, it not only adapts to diverse user needs but also sets a new standard for seating innovation.

Advancements in Multi-Layered Material Engineering: Ultra Air Mesh showcases the benefits of multi-layered material engineering, where overlapping layers and microcavities enhance airflow and strength. This innovation addresses the limitations of single-layer meshes and opens possibilities for similar designs in sportswear, medical equipment, and other applications.

Contribution to Sustainability in Product Design: Comfort is balanced with sustainability through the use of durable, wear-resistant materials, reducing the need for frequent replacements. This long-lasting design minimizes waste and promotes a more eco-friendly approach to ergonomic furniture manufacturing.