Description of the component:
As an experienced automotive supplier, OECHSLER has significantly changed the comfort and functionality of conventional car seats using additively manufactured seating elements. The result is upholstered furniture for special applications with the highest standards. These can be produced both in series and in small quantities. The new components were produced using the HP Jet Fusion 5200 Series industrial printer and the Ultrasint® TPU01 material from BASF Forward AM.
OECHSLER AG,
OECHSLER AG,
The challenge:
The development process began with an analysis of the existing car seat components. Using software design tools, the 3D designs (fixed geometry) were converted into grid structures. To identify the various pressure points during sitting, heat maps helped to visualize the data. The damping properties can be programmed depending on the geometry, thickness and size of the grid. By combining the data obtained from the seat feel and exploiting the design freedom, the damping characteristics were optimized for the respective application. The refinement of the grid structure made it possible to create a new, particularly air-permeable comfort layer, thus ensuring greater breathability and passive climate comfort. Depending on the vehicle type, harder and softer areas can be programmed to provide the desired seating experience.
In contrast to conventional manufacturing processes, additive manufacturing offers a high degree of design freedom in the production of bionic structures that enable multiple hardness zones in one cushion. Considering the challenges that car seats present in terms of ventilation, weight and space, the design process towards lattice structures is an excellent approach to meet the different requirements of the automotive industry. The final pressure test provides information about the mechanics and properties of the component. A loading and unloading curve is used to determine and compare performance. The tests have shown that the use of lattice structures delivers significantly better results compared to conventional manufacturing methods.
Solution:
OECHSLER's experience in the automotive industry and in product development was crucial to this project. Innovative approaches in product design lead to significantly more efficient downstream assembly processes, for example through the integration of additional functions such as seam channels and folding mechanisms. This results in significant savings potential during final production. The intelligent product design includes a hinge that allows large components to be produced in a single printing process. The additional integration of fixing points also eliminates the need for gluing during assembly.
In addition to the product design, the 3D printing technology, the material and the multi-stage post-processing also determine the seating experience. OECHSLER uses HP multi-jet fusion technology from HP Inc. which enables the production of flexible and functional parts. BASF Forward AM's Ultrasint® TPU01 material is approved for skin contact (ISO 10993/ OECD No. 439) and tested for durability (fatigue bending ASTM D1052), flame resistance (FMVSS 302), chemical resistance and UV resistance (ISO 4892-2A Cycle 1). Strict quality standards were taken into account during development and the other specifications required for the automotive sector in terms of fittings, odor and emissions were met. The head element is coated with Ultracur3D Coat F, developed by BASF Forward AM, to ensure a perfect match between the flexible substrate and the applied coating. The belt guide is a permanently printed component. The back element can be printed in different degrees of hardness to increase comfort. The entire seat element can be adapted to the driver's needs thanks to the grid structure. The colored elements enable a distinctive design.
The product was developed specifically for use in vehicles, although the technology and product design can also be applied to many other applications. For example, developments are already underway for other components to replace the foam that is conventionally used. Whether seating or rucksacks - upholstery is used in many different ways and can be rethought in new ways.
Conclusion:
The additively manufactured car seats from OECHSLER impress with a high level of seating comfort and, at the same time, the possibility of individualization depending on the vehicle occupants. New material properties and efficiency gains in assembly and quality make it possible to produce the car seats of tomorrow: greater comfort thanks to the choice of different hardness zones; special air permeability for passive climate comfort; lower weight; individualization through visible, colourable and programmable grid structures as well as a one-component system made of recyclable material.