The subject of the project was the development of an integral suspension system for upholstered furniture made of plastic, which is produced using the fused filament fabrication process. Up to now, suspension systems for upholstery are designed in differential construction, consisting of a seat frame, sub-suspension system and spring core. The generative manufacturing process enables a reduction of process steps and new types of seating furniture construction. When selecting suitable materials, availability was evaluated in addition to mechanical properties. Two models of an integral suspension system, with different compositions of the structural elements,
were designed, manufactured and tested. The relevant parameters for adjusting the suspension behaviour were classified in “pattern factors”. With the results, the project makes a significant contribution to the use of additive manufacturing processes for technically demanding applications and to the development of new suspension concepts. It supports the establishment of new technologies and automation in the upholstered furniture industry.