Cushions with virtual surface contouring

Abstract

A cushion with virtual contouring may have a uniform or substantially uniform thickness or height, while different locations or areas of the cushion may have different cushioning characteristics. The cushion may include a patterned grid defined by interconnected walls. The different cushioning characteristics may result from features that stiffen or soften hollow columns of the patterned grid, such as enlarged junctions between interconnected walls, voids in the interconnected walls, the thicknesses of the interconnected walls, the cross-sectional shapes and/or sizes of the hollow columns defined by the interconnected walls, the materials from which the interconnected walls are formed, layering of different patterned grids, or the like, or any combination of the foregoing. Methods for designing, manufacturing, and using cushions with virtual contouring are also disclosed.