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Interesting research, images, links, recap of regulations, etc.
video on manufacturing process of a carbon fibre based seat Status Racing - The Making of a Ring SeatÂ
video on pouring a foam insert for a bucket seat Making A Custom Foam Insert for the Race Seat
https://www.team-bhp.com/forum/technical-stuff/9521-pics-carbon-fiber-seat-how-handmade-fsae.html
https://www.instructables.com/id/Simple-methods-for-molding-fiberglass-and-carbon-f/
https://www.youtube.com/watch?v=zzQlj0zZiC4
https://www.youtube.com/watch?v=3q4GzggRumI
https://www.youtube.com/watch?v=AZasTVWY34A
https://www.youtube.com/watch?v=76E-A357ZSg
https://www.intechopen.com/books/textiles-for-advanced-applications/textile-composites-for-seat-upholstery
https://www.compositesworld.com/articles/camismas-car-seat-back-hybrid-composite-for-high-volume
Material Concepting
Concepts for what materials to use
Should be split into separate components for ease: Brace (shell), foams, and seat cover (cloths).
Brace:
Should be carbon fiber cf (the concepts of aluminum and other composite metals was discussed and the skills set needed to work with these materials cannot be done in house).
Fiberglass/Carbon fiber CF shell doesn’t improve the strength of the seat and therefore, we should if possible, use an entirely CF shell.
Foam:
Seat covering/cloth:
Mesh fabric (backpacks),
Manufacturing Concepting
Concepts for what manufacturing processes to use
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Concepts for how various materials and parts will assemble together
Foam to seat: Velcro, glue, tape, magnets
Cloth of to foam: buttons, sewing, Velcro, hooks, tape, magnets
Cloth to seat: tie, button, sew, hook, Velcro, melt, glue, tape, magnets
Proof-of-Concept Testing
What sort of testing should we be doing to ensure our chosen materials/manufacturing processes/assembly methods will work on the end-product?
Test the glue in hot and humid conditions
Test with human interaction (if moving around in the seat will cause the foam to tear or to rip the Velcro or hooks, etc)
Test if materials a comfortable (get a sample and put it on your work chair and see if you can sit on it all day)
Could include ordering samples, testing fastening/joining methods, testing assembly procedures.
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