custom contoured cushion, pressure ulcer prevention, pressure distribution, CAD/CAM Abstract. In the rehabilitation engineering area, the pressure ulcer prevention is an important and healthy problem, especially for people with the spinal cord injured (SCI). This paper aim to develop a computer aided design and computer aided manufacture (CAD/CAM) method to manufacture custom cushions to prevent pressure ulcer. A pressure sensor mat is placed between the body and flat polyurethane (PU) foam to measure the pressure distribution at the buttock-cushion interface. Based on the load-deformation characteristics of the foam material, this pressure distribution is converted into the corresponding deformation contour of the foam. Finally, the deformation data was processed and edited using Rhino 3D surface modelling software to create the CAD model of the custom contoured cushion. Then, the CAD data are transferred into CNC milling machine to manufacture the custom contoured cushion.