Manchester Metropolitan University and Levitex Foams Limited KTP 24_25 R5

A new foam device called the ‘Back Noodle’ is being developed to support the lower spine during sleep and relieve pain at the lumbosacral junction—the spot where the lower back meets the pelvis. Lower back pain is one of the most common reasons people visit their GP, yet most sleep supports are generic pillows or wedges not tailored to an individual’s anatomy. This project addresses that gap by creating a device that is systematically tested and refined using direct feedback from patients. Instead of a one-size-fits-all approach, the ‘Back Noodle’ will be optimised through a structured framework that puts the user’s experience and comfort at the centre of every design iteration. If successful, the device could offer a non-drug, non-surgical option for managing chronic lower back pain at night—a time when the spine is vulnerable to poor alignment. This could reduce reliance on painkillers and lower the burden on NHS primary care services. The project also establishes a repeatable toolkit for patient-centred product development, which could be applied to other orthopaedic supports in future. The research is applied and commercial in nature, with a clear path to market through the partnership with Levitex Foams Limited.