In order to meet the diversified rehabilitation needs of people, it is necessary to design a product for the active rehabilitation of patients. Existing rehabilitation chairs use intelligent massage, which can cause problems such as large massage areas, inability to massage locally, large chair size, and inability to meet the continuous use of the damaged parts. In this paper, the modular design method and multi-layer evaluation method are used to solve the problems related to rehabilitation chairs. The authors use the questionnaire survey method and the functional technology matrix method to determine the functional requirements of the rehabilitation chair, and then use the multilevel evaluation methods, including the AHP method, entropy weight method, and grey correlation analysis, to optimize the functional solutions of the rehabilitation chair, and finally obtain a chair for the rehabilitation of patients with upper and lower limb disorders. Problems such as the generalization of rehabilitation scope and non-durable use of components were solved, and the purpose of active exercise was achieved. This study verifies that the use of the multilevel decision evaluation method can effectively improve the efficiency of program decision-making and provides a theoretical and practical basis for the design of similar products.