Automotive Design
Car Seat Design
Year
2022
Technologies
CAD Modeling, Ergonomics, Mechanical Engineering
Role
Team Lead
The Car Seat Design project focused on developing an innovative sedan driver's seat that prioritizes comfort, safety, and market differentiation. As part of a team project, we aimed to create a seat design that addresses common pain points for drivers while incorporating advanced adjustment mechanisms and ergonomic features.
The project encompassed the complete design process from initial concept sketches to detailed 3D modeling, with particular attention to ergonomics, adjustability, and manufacturing feasibility. The final design incorporates a 30-degree tilt mechanism and rack-and-pinion adjustment system, supported by comprehensive economic and lifecycle analysis.
Applied anthropometric data and ergonomic principles to create a seat that accommodates a wide range of body types and driving positions. The design incorporates contoured surfaces that provide optimal support for the spine, thighs, and shoulders, reducing fatigue during extended driving periods. Special attention was given to pressure distribution to prevent discomfort and promote healthy posture.
Designed a sophisticated 30-degree tilt mechanism that allows drivers to customize their seating position for optimal comfort and visibility. The rack-and-pinion adjustment system provides smooth, precise movement with minimal effort, while ensuring secure locking in the desired position. The mechanisms were engineered for durability, with particular attention to wear resistance and long-term reliability.
Utilized Siemens NX for comprehensive 3D modeling and design validation. The software's advanced capabilities allowed for precise control over complex curved surfaces and mechanical components. Created detailed assembly models with accurate kinematic relationships to simulate adjustment mechanisms and verify clearances throughout the full range of motion.
Conducted thorough economic and lifecycle analysis to ensure the design's commercial viability. Evaluated material choices, manufacturing processes, and assembly requirements to optimize cost-effectiveness without compromising quality or performance. The analysis included considerations for initial production costs, maintenance requirements, and end-of-life recyclability.
Conducted comprehensive analysis of existing car seat designs, identifying strengths, weaknesses, and market gaps. Gathered user feedback on pain points and desired features to inform design priorities. Researched emerging trends in automotive seating and ergonomics to ensure forward-looking design.
Developed multiple concept sketches exploring different approaches to seat design and adjustment mechanisms. Created initial ergonomic studies to validate basic form and proportions. Evaluated concepts against established criteria and selected the most promising direction for further development.
Created detailed ergonomic models based on anthropometric data to ensure proper support and comfort for a wide range of users. Conducted simulated user testing to validate ergonomic assumptions and refine contours and dimensions. Optimized seat profile for both comfort and safety considerations.
Engineered the 30-degree tilt and rack-and-pinion adjustment mechanisms with focus on smooth operation, durability, and manufacturing feasibility. Created detailed component designs with appropriate tolerances and material specifications. Conducted motion simulations to verify proper function throughout the adjustment range.
Developed comprehensive 3D models in Siemens NX, incorporating all structural components, adjustment mechanisms, and upholstery attachment points. Created assembly models with proper constraints to simulate real-world behavior. Generated detailed engineering drawings for manufacturing reference.
Performed thorough economic and lifecycle analysis to evaluate manufacturing costs, material requirements, and long-term value. Identified opportunities for cost optimization without compromising design intent or quality. Developed production strategy recommendations based on analysis findings.
The Car Seat Design project successfully delivered an innovative seat concept that balances comfort, safety, and manufacturability. The final design incorporates advanced adjustment features that provide superior customization compared to standard automotive seating, while maintaining cost-effectiveness through thoughtful engineering and material selection.
The project demonstrates the effective application of ergonomic principles, mechanical design, and economic analysis in creating a product that addresses real user needs while considering manufacturing constraints. The comprehensive approach to the design process resulted in a solution that is both technically sound and commercially viable.
Challenge: Creating a seat design that accommodates diverse body types while maintaining consistent support and comfort.
Solution: Developed a contoured profile based on statistical anthropometric data that provides optimal support at key pressure points. Incorporated adjustable elements to allow customization for individual preferences and body dimensions.
Challenge: Designing adjustment mechanisms that remain reliable and precise over thousands of cycles.
Solution: Selected high-durability materials and incorporated self-lubricating components to minimize wear. Implemented redundant locking features and designed for serviceability to ensure long-term reliability and safety.
Challenge: Balancing design sophistication with manufacturing feasibility and cost constraints.
Solution: Utilized design for manufacturing principles to simplify production processes. Standardized components where possible and optimized assembly sequences to reduce labor requirements and potential quality issues.
Challenge: Incorporating safety features without compromising comfort or adjustability.
Solution: Designed integrated safety elements including optimized headrest positioning and reinforced structural components. Ensured all adjustment mechanisms include fail-safe features that prevent unintended movement during collision events.
