Taking 'Not a Wheelchair' to the NEXT LEVEL? – New Factory Tour!

The company, which previously manufactured off-road wheelchairs, has expanded to produce everyday manual wheelchairs, aiming to save the wheelchair community money. Operating in "stealth mode" for the past year, they've already saved about $2 million. Their Paradox wheelchair is highly customizable, offering over 16 quintillion unique options, emphasizing that each person and wheelchair is different, much like a glove fitting a hand. This video is for two types of viewers: those interested in complex manufacturing, given that no two wheelchairs are identical, and manual wheelchair users, as it details the measurement and building process. The factory in Utah takes raw aluminum tubing and produces a custom wheelchair within weeks, at 60-70% less cost than competitors, addressing the challenges of insurance. Several users shared their experiences: Camry, a wheelchair user for 20 years due to a horse accident, reported her last insurance-covered chair cost $8,000 and took a year to receive, while her Paradox chair was $1,900 and delivered in 6-8 weeks. Bailey, injured 7 years ago, paid $10,000 for her previous chair, which took 6 months, but her Paradox chair was $2,100 and arrived in 6 weeks. Dade, injured 9 years ago in a car accident, spent $5,000 on his insurance chair, waiting 6 months, while his Paradox chair was $2,300. Another user, injured 3.5 years ago, paid $12,000 for her first insurance chair, which took 6 months, but her Paradox chair cost $1,649 and arrived in 5 weeks. The company boasts faster and cheaper production, with chairs starting at $999, even with upgrades. The customization process begins with color, offering over 6,000 combinations since all powder coating is done in-house, adding minimal time to the build. Users can preview colors on their website configurator, a feature unique among wheelchair companies. The speed of production is attributed to the entire factory and machines being located in the USA. The process starts with a state-of-the-art laser cutting frames in minutes, followed by a CNC bender that precisely shapes tubes, capable of bending 250 wheelchairs daily. TIG welding, requiring a human touch due to customization, is the next step, with future plans for robotic fixturing to further reduce lead times. Final assembly brings together the seatpan, axle tubes, casters, rear wheels, and backrest. Seat type is a personal preference; 70% choose a soft seat sling, while 30% upgrade to a carbon fiber or aluminum hard seat. Seat width is not adjustable post-production, so accurate measurement is crucial. This involves measuring between the clothing guards, ensuring light contact with the hips without pressure. The measurement is taken to the nearest half inch, from the outside of one tube to the outside of the other. For those with hips wider than knees, a seat taper can be added, narrowing the front edge by 1.5 inches to eliminate wasted space and match the user's footprint. About 10% of customers choose this option, though most off-the-shelf cushions are rectangular. Seat depth is another body-dependent dimension, requiring full support from the lower back to the inside crease of the knee, without touching the back of the knee to prevent rubbing. The full measurement is taken, then 1 to 1.5 inches are subtracted. For example, Camry's hip-to-knee measurement of 16 inches results in a 14.5-inch seat depth after subtraction. For frame type, half of users choose the no-taper option as it's the least expensive. However, Y-taper or V-taper options reduce the chair's footprint and allow tighter turns. The Y-taper is slightly more popular, and both cost the same, quickly produced by the CNC bending machine. The Y-taper is preferred by some for easier footplate adjustment. It's important to ensure the distance between the tubes is not narrower than the widest pair of shoes. Frame supports can be added for increased stability and stiffness, especially for outdoor activities or heavier users. Rear seat height is measured from the floor to the back of the seatpan, and front seat height from the floor to the front edge. The difference is called seat dump or slope. About 50% of people prefer 1.5 to 2 inches of seat dump, but it's a personal preference; some with higher-level injuries prefer more slope. Dade, for instance, has a 17-inch rear seat height and 19-inch front seat height, resulting in a 2-inch slope. For those without an existing chair, front seat height can be determined by adding seatpan-to-footrest measurement to ground clearance, then subtracting the desired dump for rear seat height. Frame depth extension is also a personal preference, offering more to hold onto during transfers and slightly improving stability by lengthening the wheelbase. About 25% prefer no extension, while 50% extend it by 1 to 1.5 inches. The front angle concerns the curve of the wheelchair from the seat to the footplate. About 20% prefer a 90-degree angle from the ground, while 60% opt for an 85-degree angle, which slightly extends the footplate for improved stability, though it increases the chair's footprint. Backrest height is a personal preference and adjustable post-delivery. When sitting upright, the backrest should be lower than the shoulder blades to allow arm movement for pushing while providing support when not pushing. The backrest angle is relative to the seatpan's slope. Most people (60%) choose 90 degrees, as the seatpan is already slightly reclined. About 20% recline the backrest further to 95 degrees, but this is also adjustable. The seat posts are always 90 degrees to the seatpan; only the backrest itself adjusts. Seat-to-footrest measurement is from the seatpan to where the heels rest on the footplate. When measuring from heel to the back of the knee, account for the 2-3 inch cushion, but the configurator only needs the measurement from the bottom of the seatpan to the top of the footplate. Measurements should be taken while wearing typical shoes. The footplate height has 1-2 inches of adjustment after delivery. The online configurator shows real-time dimensional measurements, ensuring accuracy. Casters are the next choice, with standard options or "frog leg" casters offering more suspension. Anti-tippers and retracting push handles are also available. Hand rims include standard aluminum or wooden options, with some users preferring wood for warmth in winter, while others dislike the texture. Center of gravity is crucial for popping wheelies. About 50% choose 2.5 inches when measured from the backrest post to the wheel's center. The axle is adjustable, but getting it close to preferred settings initially is beneficial. For wheel camber, 75% choose 2 degrees for a stable foundation. Dade uses a 4-degree camber for a wider stance. Wheel diameter is personal, with 75% choosing 24-inch wheels; 25-inch wheels are an option for taller users or a sportier chair. The frame with wheels weighs about 26 lbs, and without wheels, it's about 18 lbs. Wheelchair armor from Dbrand is available for protection against scuffs and dings, being easy to apply and replace. Finally, users are encouraged to use the numerical drawings on the configurator for a sanity check, as the 3D rendered chair is exactly what will be shipped. The manufacturing process for a custom lightweight wheelchair is intense, and checking measurements with an ATP or seating specialist is recommended. The goal is to build and ship wheelchairs in a few weeks, with an expedited paid option available. Users should allow a few days to adjust to a new chair, as there is some post-delivery adjustability. Sharing this video is encouraged to help more people save money.