Product Designer
Final Final.41 cropped.png

Form

A lightweight economy aircraft seat for high density configurations, designed as part of a 16 week major project.

The backrest morphs to provide support and reducing pressure points that lead to discomfort over time. Passengers have higher comfort levels, while lightweight construction means airlines save money on fuel costs.

Building upon tested designs.

Building upon tested designs.

A strip down of an existing B/E Aerospace economy aircraft seat showed how components were attached and the materials they were made from. This helped to influence design for manufacture throughout the project.

Initial concepts.

Initial concepts.

Initial concepts were drawn based on the existing backrest construction to utilise space for passengers.

Developing concepts.

Developing concepts.

Incorporating the new backrest structure which works based on the finray effect, a number of different backrest shapes were designed which would not be possible with the existing construction.

Research with leading experts.

Research with leading experts.

Developed concepts for the backrest were taken to TU Delft. A discussion with Prof. Peter Vink showed possible ergonomic improvements.

The visit also showed current experiments based on improving passenger comfort for economy passengers, and how changing the amount of space a passenger has will affect their comfort and discomfort.

Concept refinement.

Concept refinement.

After refining the shape of the backrest and seat, details were refined on all aspects of the seat including the armrest, backrest and frame structure.

The final design.

The final design.

Form is a lightweight economy aircraft seat for high density seat configurations which looks to increase passenger comfort but not at the cost of airlines or an increase in passenger fares.

The preliminary new design weights under 24kg per triple (8kg per pax). This is in line and exceeding some current products which are on the market for weight, and so can provide airlines with a lower cost of ownership through savings in fuel costs.

High density, high comfort.

High density, high comfort.

The new backrest design means that it’s shape contours to the shape of the user, reducing the number of pressure points.

This design means the high levels of cushioning normally required to increase the comfort is less, and so airlines can maintain a high density configuration within the cabin.

A seat with a view.

A seat with a view.

Visuals were created within an interior model of an Airbus A320 on Keyshot to display the final product in context.

Suitable for use.

Suitable for use.

Parts were manufactured so that they would be usable for the life of the product. This included extensive ribbing in polymer components such as the armrest, which would undergo thousands of stress cycles throughout its life.

Suitable materials were used for the components so that they could be used inside an aircraft interior. This included PPSU, flame retardant TPU, ABS/PVC cladding sheets and aluminium.

Suitable for manufacture.

Suitable for manufacture.

Parts were designed with manufacture in mind. A number of parts had engineering drawing showing all tolerances, dimensions and finishes with datum planes required to manufacture the part.