Guide to Wheelchair Manufacturing Processes
Ageally gives you a complete guide of how wheelchairs are made, from building the frame to putting it all together and testing it with users. We’ll also show you what materials we use, the important steps in production, and how we make sure everything is top quality.
Table of Contents
Basic Steps of Wheelchair Manufacturing Processes


The first step in making a wheelchair is to build the frame, which is the most basic part and has the biggest impact on how well the vehicle performs. Frames can be foldable or solid and are usually made from materials like steel, aluminum, titanium, or carbon. The choice of material affects how heavy the wheelchair is, how long it lasts, and how easy it is to move around.
The lengths of metal materials such as extruded aluminum are cut, drilled, and shaped for the wheelchair components. Metal drop-saws are used to accurately cut individual components to size, and then the pieces are set up in jigs mounted on drill presses and drilled as needed. This ensures that the frame construction is precise and consistent.
The next step is all about making different parts for wheelchairs, like wheels, armrests, and seating. We use materials such as rubber for the armrests and wheels, and upholstery for the seating to make sure it’s comfortable and supportive for the user.
The production of various wheelchair components from aluminum bar, angle, and plate stock is carried out using four computerized CNC milling machines. Skilled volunteers program these machines to ensure that the parts are always dimensionally accurate and have a high-quality finish.
The main modules are put together by attaching the frame, wheels, and other components. This process needs to be done with precision to make sure all parts fit together correctly and work as they should. The assembly is really important for how well the wheelchair performs and how long it lasts.
The process of quality testing is super strict to make sure it meets wheelchair WHO guidelines and ISO7176 standards.
This includes putting it through stress tests and durability assessments to check if it can handle daily use and be reliable in the long run.
The final steps involve packing the wheelchair with any extra items like cushions or supports, so that it’s all set for delivery and tailored to meet the user’s specific needs.
Build the Frame of Wheel Chair
The first step in making a wheelchair is to build the frame, which is like the backbone of the wheelchair. Usually, this frame is made from materials like aluminum, titanium, or steel. Each of these materials has its own advantages: aluminum is light and strong, titanium is tough and resistant to rusting, and steel offers strength and affordability.
Common Materials of the Frame

Wheelchair frames are typically made of lightweight yet strong metals such as aluminum or steel. The specific alloy and thickness of the material will depend on the desired strength and weight of the wheelchair.
The frame construction of wheelchairs often uses lengths of extruded aluminum. These lengths are cut, drilled, and shaped to make the different wheelchair components. Metal drop-saws are used to accurately cut the individual parts to the required sizes. This precision is important to ensure that all the pieces fit together perfectly during assembly.
After being cut, the components are placed in jigs mounted on drill presses for drilling as needed. This step ensures that all the necessary holes are accurately positioned for later assembly. The drilled components are then moved to different areas within the workshop for further processing and assembly into sub-units.
Bending
The bending process of wheelchair frames is a crucial step in manufacturing. It involves shaping the metal tubing into the desired curves and angles to form the frame of the wheelchair.
Rotary draw benders, roll formers, press brakes, and tube bending machines are the primary equipment used in the bending process.
The bending of wheelchair frames is a complex process that requires careful planning and execution. The choice of bending method depends on factors such as the material, the desired shape, and the production volume. By combining advanced manufacturing techniques and precise engineering, manufacturers are able to produce wheelchair frames that are both strong and lightweight.
Frame Welding

The process of welding is super important when it comes to building frames, especially for materials like aluminum and titanium. You gotta use special techniques and equipment to weld these materials together so that the joints are strong and durable. It’s crucial to control the welding process with extreme care in order to avoid any weak spots that could mess up the frame’s strength.
The material for titanium frames is shaped and welded together to perfectly match the wheelchair user’s body shape, without compromising on strength. This customization ensures that the final product fits like a prosthetic, seamlessly extending the user’s body with unparalleled durability and strength.
In addition to welding, some components can also be put together using bolts and other fasteners. This way, it’s easier to make adjustments or do repairs when needed. The decision on whether to weld or bolt depends on the specific design and material of the wheelchair frame.
Wheel Chair Components Production
The production of wheelchair components is a meticulous process that involves using different materials and advanced manufacturing techniques. Key components like wheels, armrests, and seating are carefully made to ensure they work well and provide comfort for the user. The materials used in these parts range from metals such as aluminum and steel to plastics and fabrics, each chosen for their specific properties and advantages.
Wheels

Wheels are super important for any wheelchair because they give it the ability to move around smoothly and stay steady. Usually, they’re made from tough materials like rubber and aluminum. Also, the medical casters is important, it provide mobility to medical equipment, allowing it to be easily moved from one location to another.
The manufacturing process involves cutting and shaping these materials with fancy computer-controlled machines to make sure they’re just the right size, which guarantees top-notch quality every time. After that, the wheels are put together with bearings and axles so that you can count on them for a smooth and reliable ride.
Motor
The motor of an electric wheelchair is typically a direct current (DC) motor, it offer power to drive the electric wheelchair to move.
Electric wheelchair motor provides high torque at low speeds, this is essential for providing the necessary power to move the wheelchair in heavy load conditions. For electric wheelchair manufacturer, they use a radiator machine to make a standard radiator, which helps the motor to dissipate heat quickly, so the electric wheelchair is at a suitable working temperature and provides stable and sufficient power.
Armrests

The purpose of armrests is to give the user support and comfort. They’re usually made from a mix of metal or wood for the structure, and hard plastic, fabric, or solid urethane for the padding.
The choice of padding material is super important because it affects how comfy they are; breathable and soft fabrics like nylon and vinyl are really popular options. To make a cozy and supportive armrest, these materials go through cutting, shaping, and assembling in the manufacturing process.
Seat
The seating is another important part that needs careful consideration when it comes to materials and design. The seat is usually made with tough upholstery that can handle daily use while providing comfort. The manufacturing process involves cutting and sewing the fabric to fit the frame perfectly. Additionally, the seat frame, often made from lightweight yet strong aluminum or steel, is designed for easy use and long-lasting durability.
Advanced Manufacturing Techniques
Advanced manufacturing techniques like CNC milling are used to make different parts of wheelchairs.
Why you should use CNC milling machine?
- These machines are controlled by computers, ensuring that each part is accurate and consistent in size, which is very important for the overall performance and safety of the wheelchair.
- Skilled technicians program these machines to precisely cut, drill, and shape materials, resulting in components that meet strict quality standards.
Pre-made Parts
The final product is made by putting together pre-made parts. For example, we add handles, harnesses, and brake components to the seat modules, and combine steel chassis frames with seat units, footplates, and brake units to make complete chairs. We pay a lot of attention to detail during this process to make sure that each wheelchair works well and feels comfortable.
Assembly of Modules
The assembly of wheelchair modules is a careful process that makes sure each part is securely and accurately attached to create a functional and dependable mobility aid. This process starts with putting together the seat, back, and footrest modules. Plastic blanks for these parts are drilled at workstations equipped with jigs to guarantee precise and consistent adjustments.
After drilling the plastic blanks, we put them together with aluminum seat framing. Then we attach the footplate plastics and add in the seat modules, handles, harnesses, and brake components. This step is super important because it creates the foundation of the wheelchair and makes sure everything is lined up perfectly.
The next step is to put together the steel chassis frames with the pre-assembled seat units, footplates, and brake units. This combination creates a complete chair, except for the two main wheels. The steel chassis provides the necessary strength and durability, while the aluminum seat framing ensures a lightweight and easy-to-handle structure.
After the main modules are put together, we attach the front jockey wheels to the steel chassis. These wheels are super important for making the wheelchair easy to move around and keeping it stable on different types of ground. We check and adjust how these wheels line up to make sure everything runs smoothly.
The final step in putting the wheelchair together is attaching the two main wheels. These wheels are super important for making sure the wheelchair can move around, so they need to be fastened really securely to the frame. The assembly process makes sure that everything is lined up correctly and attached properly, so you end up with a strong and long-lasting wheelchair that’s ready for quality testing.
Quality Testing

The quality testing phase is super important in wheelchair manufacturing, making sure that each unit meets the strict guidelines set by the World Health Organization (WHO) and ISO7176 standards. This phase includes a bunch of tough tests designed to check how strong, durable, and safe the wheelchair is under different conditions.
Strength Tests
The testing procedures start with static strength tests, which check if the wheelchair can handle static forces without getting bent or broken. This is super important to make sure that the wheelchair can support the user’s weight and any extra stuff it might come across during use.
Resistance Test
We test the wheelchair’s impact resistance to see how it handles sudden shocks and collisions, which is crucial for user safety in real-life situations.
Durability Test
Durability assessments involve fatigue testing, where the wheelchair goes through repeated cycles of stress to mimic long-term use. This helps pinpoint potential weak spots and ensures that the wheelchair can handle daily wear and tear over a long period of time.
Brake Test

The effectiveness of the brakes is another important aspect of quality testing. We evaluate the wheelchair’s braking system to make sure it can reliably stop and hold the wheelchair in place, giving the user control and safety on different surfaces and slopes.
Environmental Test
The wheelchair’s performance is also tested in different environmental conditions to see how it holds up. This includes exposing it to dirt, moisture, and changes in temperature, which can affect its parts and overall functionality.
Periodic Test
The periodic testing, following WHO guidelines, includes timed duration tests on simulated rough terrain and drop/impact testing. These tests make sure that the wheelchairs meet international standards and simulate the conditions they may encounter in real-life situations, especially in developing countries.
Whenever there’s a design change or new component added, the wheelchair goes through retesting following ISO7176 standards. This ongoing evaluation process helps maintain high-quality and safety standards, making sure that any modifications don’t compromise the wheelchair’s performance.
Governments are encouraged to develop and adopt national standards for wheelchairs based on the ISO7176 series in order to ensure that wheelchairs of reasonable quality are available. These standards should apply to all wheelchairs sold within a country, regardless of whether they are produced domestically or imported.
Long-term Follow-up Studies
The wheelchair’s performance and durability should be monitored in the long run to see how it holds up over time. This ongoing evaluation helps us catch any issues that might come up with extended use and gives us valuable feedback for improving future designs.
Packing and Ancillary Items
The final steps in the wheelchair manufacturing process involve carefully packing and including extra items to make sure the product is ready for distribution. After going through rigorous testing and final adjustments, each wheelchair is individually wrapped up. This wrapping process is super important to protect the wheelchair during shipping and make sure all parts arrive in perfect condition.
Each wheelchair is packed in sturdy, donated boxes that are clearly labeled to list exactly what’s inside. This includes all the main parts of the wheelchair as well as any additional items needed by the person using it. The packaging process is designed to be efficient and thorough, making sure nothing gets missed.
The wheelchair package also includes extra stuff like comfy cushions, rugs, and toys. These things are super important to give the user more comfort and support. Like, a good cushion is really necessary for relieving pressure and helping with posture, especially for people who can’t feel their skin well and might get pressure sores.
Including these extra items isn’t just about comfort; it’s about making sure the wheelchair user stays healthy in the long run. A well-designed cushion can make all the difference between living an active, independent life or dealing with health issues. That’s why manufacturers either keep a good variety of cushions in stock or have the ability to produce and customize them as needed.
The packaged wheelchairs are finally ready to be exported. We make sure everything is packed securely and the packaging is strong enough to handle the rough journey. Our aim is to deliver a fully functional wheelchair that’s good to go, meeting all quality standards and user requirements.
Material Selection
The choice of materials is super important in making wheelchairs because it directly affects how strong, light, and well the wheelchair performs. Aluminum, titanium, and composites are the most commonly used materials with each having their own pros and cons.

Aluminum
Aluminum is a popular choice because it’s lightweight and durable. High-end wheelchairs often use super strong aircraft-grade aluminum alloys, which allow for thinner frame tubing and save weight. This makes aluminum frames perfect for active users and those using powered add-ons.
One of the great things about aluminum is that it doesn’t rust, so it lasts a long time even in tough conditions. But the downside is that it can easily get dented and scratched, plus it’s generally more expensive than steel.
Titanium
The use of titanium is highly respected in wheelchair manufacturing. It’s even stronger than aluminum, which means frames can be made even lighter without sacrificing strength. Titanium’s amazing ability to resist fatigue and dampen vibrations makes it a durable and comfortable choice for users.
Despite all its advantages, titanium is way more expensive than aluminum. Plus, while it gives you a smooth ride and can handle dents and scratches like a champ, it’s not as sturdy, which might make some users uncomfortable.
Carbon Fiber
Composites, especially carbon fiber, are like the best of the best when it comes to wheelchair frame materials. Carbon fiber is like five times stronger than steel and twice as stiff, but it’s way lighter and super durable. That’s why it’s perfect for those fancy, lightweight models made for experienced users.
The thing is, carbon fiber wheelchairs aren’t as adjustable as aluminum ones, so they’re not the best choice for users who need to make frequent changes. Plus, they can easily chip and are pretty pricey.
In conclusion, when choosing the material for a wheelchair frame, it really depends on what the user needs and how much they can spend. Aluminum is a good choice because it’s strong but not too heavy.
- Titanium is even better because it’s super strong and comfortable.
- And if you want something really lightweight, carbon fiber is the way to go. Knowing about these materials will help you make the best decision for your own comfort.
Customization Options
Customization options for wheelchairs are crucial to meet the diverse needs of users. These options include adjustable seating, which is super important to make sure you’re comfy and sitting right. For example, wheelchairs can be fitted with special cushions to prevent pressure sores, especially for people with spinal cord injuries or similar conditions.
Adjustable Seat & Backrest
The seating can be adjusted, but that’s not the only way you can customize your wheelchair. You can also add a firm backrest like the Ageally wheel chair range to give you more support and help you stay upright. This is especially important for people who need extra stability and support.
Adjustable leg angles & Armrests
The wheelchair can be customized to fit your needs, including adjusting the leg angles and armrests. You can choose the specific leg angles and supportive armrests that will make you feel more comfortable and improve functionality. Moreover, we can add lateral supports to help you maintain an upright posture, which is crucial for individuals with unstable spines or at risk of developing secondary deformities.
The wheelchair model should have good adjustability for users whose conditions may change over time. This way, you can modify the wheelchair to fit your changing needs and ensure long-term comfort and usability.
Customization of Wheelchairs
The customization of wheelchairs also involves choosing different components like wheels, armrests, and seating. These components can be personalized to meet the specific needs of the user, making sure that the wheelchair is not just functional but also comfortable and supportive.
The customization options for wheelchairs are also influenced by the environment they will be used in. For instance, outdoor wheelchairs need to be tough and able to withstand more wear and tear compared to indoor ones. This includes considering exposure to moisture, extreme temperatures, and rough terrains.
Customizing a wheelchair goes beyond just its physical components. You can add accessories like trays, holders for oxygen tanks and cups, as well as bags to make the wheelchair more functional and convenient. This way, it becomes easier and more comfortable for the user in their daily life.
Production Scale
The scale of wheelchair production is a crucial aspect of the manufacturing process, showing how capable and efficient the production facilities are. For example, Wheelchairs for elderly in China, a well-known manufacturer, churns out around 3000 wheelchairs every month. This impressive production rate is achieved through a streamlined process that involves various stages from constructing the frame to final assembly and testing.
Cost of a Wheelchair
The cost of a wheelchair can vary depending on what you need and the extra stuff you want. At Wheelchairs in ageally, it’s around $280 to $1300 per chair. That price includes everything – materials, labor, and any special features that might be necessary for the user’s specific needs.
Standardization (ISO)
The production process is designed to make sure that every wheelchair meets strict quality standards, including those set by the World Health Organization (WHO) and the International Organization for Standardization (ISO). By adhering to these high standards, we ensure that our wheelchairs are not only functional but also long-lasting and safe for users.
The production scale is also affected by the availability of skilled workers and advanced manufacturing equipment. For instance, using computerized CNC milling machines allows for precise and consistent production of wheelchair components, which is crucial to ensure high quality in all units produced.
Besides making standard wheelchairs, manufacturers often have to offer customization options to meet the diverse needs of users. This can include adjustable seating, specialized components, and other modifications that may impact both production scale and cost per unit.
The production of wheelchairs is a complex mix of different factors, like how many can be made, managing costs, making sure they’re good quality, and meeting people’s specific needs. By getting all these things right, mobility aids manufacturers can make sure there are always plenty of great wheelchairs available for people all over the world.