Composite Aircraft Seat

The Approach

In less than a year, DAE successfully designed, prototyped, tested, and certified the new seat for flight. Leveraging automated manufacturing processes, the team eliminated the potential for process errors, ensuring high-quality parts with consistent performance. CAE was utilised to simulate structural tests, predicting stiffness, strength and impact performance crucial for certification. The seat was engineered to absorb energy during impact scenarios while prioritising passenger safety. Variances in seat distances catering to the requirements of our client, added complexity to the design process.

Composite materials were chosen to meet weight reduction goals while stringent fire and heat resistance requirements posed challenges. Extensive research was conducted to identify materials that could be processed quickly without compromising structural integrity. Simulation, prototype manufacture and physical testing were employed, which validated structural performance and resistance to fire, smoke and toxicity emissions.

Drawing on our experience across the transport industry, DAE utilised a combination of commercial and in-house software for swift and accurate structural evaluations. Rapid processing methods and in-house tool manufacturing capabilities enabled DAE to meet production volumes and ensure timely project completion.

DRVN Advanced Engineering delivered a certified composite lightweight commercial aircraft seat that surpassed performance benchmarks while achieving weight reduction objectives. The automated manufacturing process ensured consistency and high-quality output, meeting stringent industry standards. The successful integration of composite materials and rapid processing methods underscores DRVN’s commitment to innovation and excellence in aerospace engineering.