Biomechanical optimization of multilayer mattress designs using finite element modeling: Effects of egg-crate topography on pressure redistribution

This finite element study investigates the biomechanical design of a multi-layer orthopedic mattress, with particular focus on optimizing a specialized egg-crate foam top layer integrated within a tri-layer support system. While minimizing stress concentrations caused by surface protrusions was one key objective, the broader research aim was to develop a comprehensive mattress architecture where each layer – including a transition mid-layer and supportive base – serves distinct mechanical functions. The topographical surface geometry was carefully coupled with tuned hyperelastic properties to achieve dual objectives: reducing interface pressure peaks while maintaining system-level structural integrity and load distribution. Computational results demonstrate that the proposed multi-layer design demonstrates improved mechanical performance. The compliant egg-crate configuration reduced maximum principal logarithmic strain by 58%–62% and peak contact pressure to 0.024 MPa, while maintaining adequate support through optimized stress transfer to underlying layers. Importantly, the study identifies critical design thresholds beyond which surface texturing becomes counterproductive, providing valuable insights for therapeutic mattress engineering. This work establishes an integrated approach to patient support surface design, advancing beyond conventional single-layer optimization to address the complex biomechanical interactions in multi-layer mattress systems for pressure ulcer prevention.