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In this paper we present a seat design concept that results in significant (20%-40%) weight savings in automotive seat cushions. This concept replaces the traditional flexible foam and steel frame with an alternate lightweight concept using structural foam technology. Additionally, this design concept uses comfort cutout areas, which allow optimization of seating comfort. To develop and prove this concept, we explain the methodology used, including design concepts, computer simulation, manufacturing processes, assembly considerations, and testing. The materials used are characterized and modeled for use in virtual development, including comfort and crashworthiness. Traditional assembly techniques are reexamined and optimized for time and cost. The overall economics of the concept are shown. Finally, the design is tested to verify the real world performance.

Position of the H-point plays a vital role during designing the seating system. The seating system provides support and comfort to the occupants while they are operating the vehicle. The traditional way to design a seat system is to use rules of thumb and experience, which often results in several costly design iterations. The purpose of this paper is to demonstrate the capability of CAE analytical tool to find the H-point at the early phase of the seating system design without compromising the comfort level of the occupant. The recently launched Lincoln Continental front seating system was used to validate this purpose. The Continental seating system has unique design features which provide special challenges in designing and simulating the seat. With the help of CAE analytical tool, the traditional process is streamlined and a seat design could be achieved in a shorter period with greater accuracy.