This study presents a reverse design and additive manufacturing approach for custom furniture protective foot covers. Using flexible polylactic acid (PLA) filaments, the foot covers were designed and manufactured to fit the shape of chair feet. The process involved 3D scanning, reverse design, and additive manufacturing. The foot covers provided cushioning and noise reduction, improving the comfort and safety of furniture movement. Finite element simulation showed a 90.8% reduction in stress when the chair fell vertically, and noise tests revealed a 51.0% decrease in noise. The foot covers were made using FDM 3D printing with flexible PLA filament, and the design process included 3D scanning, mesh processing, and reverse design. The results demonstrated the effectiveness of the foot covers in reducing damage and noise, offering a practical solution for furniture protection. The study highlights the potential of reverse design and additive manufacturing in creating customized protective products.This study presents a reverse design and additive manufacturing approach for custom furniture protective foot covers. Using flexible polylactic acid (PLA) filaments, the foot covers were designed and manufactured to fit the shape of chair feet. The process involved 3D scanning, reverse design, and additive manufacturing. The foot covers provided cushioning and noise reduction, improving the comfort and safety of furniture movement. Finite element simulation showed a 90.8% reduction in stress when the chair fell vertically, and noise tests revealed a 51.0% decrease in noise. The foot covers were made using FDM 3D printing with flexible PLA filament, and the design process included 3D scanning, mesh processing, and reverse design. The results demonstrated the effectiveness of the foot covers in reducing damage and noise, offering a practical solution for furniture protection. The study highlights the potential of reverse design and additive manufacturing in creating customized protective products.