A Johnson Controls team, working with a newly developed seat structure, succeeded in reducing the use of steel and light alloys by replacing them with multi-material systems. The CAMISMA seats are more than 40 percent lighter than conventionally manufactured seat structures made of metal and can be produced at a better cost, the company says, also reporting that the results of an initial rear-impact crash test demonstrated that the CAMISMA seat prototype satisfied all of the strength requirements of current seats built with a metal structure in large-scale series production.  

Johnson Controls has now successfully tested the first functional prototypes under conditions similar to those in series production, developing an industrial manufacturing process for volume production with about 200,000 units per production line.

"Although carbon-fiber products generally offer outstanding characteristics, such as great strength and design flexibility, they are too expensive for use in the large-scale series production of vehicles," said Andreas Eppinger, group vice president technology management, Johnson Controls Automotive Experience. "With CAMISMA our goal was to create cost-efficient, sustainable access to carbon-fiber-based materials systems."

Sustainable solution

The manufacturing steps required in assembly are substantially reduced through the number of attachment parts needed, which also saves cost. These seats will be available in vehicles in 2019.

The CLEPA Innovation Award jury, which recognised the company in the “Green” category, reportedly called CAMISMA an “outstanding, future-oriented solution for sustainable CO2 reduction”.