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The prevention of pressure ulcers remains a significant problem in rehabilitation engineering, cushion takes an extra important role in the prevention of pressure sores for high-risk people who require wheelchairs for movements. The aim of this study was to design a cushion preventing pressure ulcers. A new efficient method to manufacture custom-contoured cushion (CCC) was proposed, and clinical research was carried out to test the effectiveness of the new kind of custom-contoured cushions (CCCs). Twenty-eight subjects, twelve healthy participants with long-time sitting per day and sixteen spinal cord injured patients, agreed to participate in this study. The outcomes showed that CCC could redistribute the pressure under buttocks, decreased the peak value and mean value of pressure, reduced pressure gradient, and improved sitting balance evidently. The participants had increased subjective feeling of comfort and stability with CCC. The results also revealed that there was a positive correlation between the mean value of pressure and Body Mass Index (BMI) of participants.