Solutions: F250 Seat Composite Cushion Frame

Ford F250

Ford F250

The Challenge

Replace magnesium die cast, a known light weight material, with a plastic alternative at a lower cost point with greater flexibility in terms of design and cost while satisfying all Safety and Crashworthiness requirements.

Our Solution

Royal technologies worked closely with Ford, the resin supplier and tool shops to develop an industry first application of a composite material into a 2-point pivoting structural set cushion frame. This new solution provided a significant cost and weight reduction, improved the carbon footprint as well as earned Ford an SPE award and 4 US Patents.

Previous Situation Our Solution Awards

Previous Situation

  • Magnesium die cast cushion frame.
  • Existing Magnesium tooling required constant maintenance
  • Magnesium part requires secondary de-flash operation
  • Magnesium part requires specialty fasteners to attach to seat structure and plastic latch
  • Magnesium as a material is more expensive when compared to a composite plastic.
  • Magnesium applications worldwide have significantly larger carbon footprint compared to plastic composites.

Our Solution

  • First industry application of 40% LF GF-PP composite material in a combination 2-point pivoting structural seat cushion frame
  • Meets or Exceeds all NHTSA and FMVSS requirements
  • Improved crashworthiness using energy absorbing EPP anti-submarine block
  • Meets Jounce durability, Console System Static and Cycle Loads
  • Eliminated use of specialty fasteners for magnesium thread forming
  • Offers an open architecture for future add-on features such as:
    • Cargo hooks, Straps, and Unique Flexible Storage Features
  • Inter-changeable (lock vs. non-lock) latch provides customer personalization

Awards

Winner of SPE 2016 Safety Award

Solution Benefits


Browse More Solutions

F250 Seat Composite Cushion Frame

Ford F250

A plastic alternative at a lower cost point with greater flexibility

Precision Optics

Precision Optics

One of our customers asked us to help make their automotive safety lenses even more precise.

Zody Chair Back Assembly

Zody Chair

Taking a prototype design for a revolutionary new task chair and making it production-ready.

Automotive Side Shield

Side Shield Front

Creating a less expensive, easier to produce, and more flexible automotive side shield.

Cut TDI to Molded MDI Foam

Foam Production

Taking a complex cushion and making it simple, less costly and more comfortable.

Aeron Chair Arms

Aeron Chair

Developing an environmental-friendly, low-cost, light-weight arm rest for a world-renowned product.

File Compressor Conversion

Plastic can offer several advantages of steel with none of the disadvantages

Our file compressor weighed less than 30% of the original and costs 30% less.

Arm Assembly Redesigned

Redesigned Arm

Lowering production costs by nearly 15% while improving product strength and ease of assembly.