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Could include ordering samples, testing fastening/joining methods, testing assembly procedures.

Seats Manufacturing

Seats Cushions:

Materials:

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1. Using the 2 part epoxy (DP-420) (making sure to pull the neoprene over the edges of the seat back) adhere to seat back and seat pan

2. Adhere the polyethylene closed cell to the neoprene with the tape/spray (the foam will need to be pressed down with a weight and left for 1-3 hours to dry). The tape/spray should be applied to both sides of the cushioning.

3. Place the open cell on the areas that need to be padded based on the mockup (again use the tape/cement spray to secure the soft open cell to the closed cell)

4. The contouring of the foam will need a jig

How to construct the jig:

Seat Pan:

Materials:

·        Carbon fiber flat panel from the flat panel (2 layer carbon fiber each side)

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1. Take CAD mold and CNC them

2. Line mold with wax (anti-peeler)

3. Take the carbon fiber and (2 layers) and vacuum bag (about 24-48 hours)

4. Place in the nomex and coat with resin (vacuum bag again) (about 24-48 hours)

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1. Place 1 layer of Kevlar onto the nomex in the shoulder area (between head and top of shoulder)

2. Place the final 2 layers of carbon fiber and vacuum /back again (about 24-48 hours)

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1. Slowly remove from the mold

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1. Cut foam to fit inside the seatback (please see assembly doc)

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1. Adhere foam together with the tape/spray (will need to be clamped down)

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1. After the foam has uncompressed adhere it to the seat back with DP-420 (the carbon fiber will need to be cleaned with acetone and sandpaper before using the adhesive)

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1. Adhere extra support to the foam with the tape/spray (side cushioning, bolsters, lumbar, and headrest)

Seat Supports:

Materials:

·        Carbon fiber flat panel

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