A leading powersports brand faced a complex challenge. They needed to enhance the ergonomics and reduce the weight of the seat shell for a flagship off-road vehicle. All this, while also achieving significant cost savings. The goal was to deliver a superior ride experience without increasing the vehicle's price point, which could negatively impact sales.
The Comfort Equation: Balancing Innovation and Design
Seat shells in powersports are critical components. They must absorb the intense shocks and vibrations of a rough ride while providing a comfortable and supportive experience for the rider. The existing design met basic requirements, but the brand saw an opportunity to innovate. They aimed to improve ergonomics for long-duration comfort and lightweight the component for better vehicle performance. However, these improvements could not come at the expense of durability or lead to higher production costs.
Engineering Momentum: Building a Better Seat
Formerra stepped in to lead the project. We coordinated and managed over 150 hours of intensive engineering support, working as a seamless extension of the client's internal team. Our collaborative approach focused on developing a more durable and cost-effective seat shell design. By combining our materials expertise with advanced engineering principles, we explored innovative ways to redefine the component's geometry and material composition.
Results that Go the Extra Mile
Our collaborative engineering drive delivered outstanding results. The reimagined seat shell not only demonstrated a 30% boost in strength over the previous design—enhancing both durability and rider safety—but also enabled seamless part consolidation. This smart redesign simplified the manufacturing process and delivered significant cost savings. We successfully enhanced both comfort and performance while simultaneously reducing expenses.
Lessons from the Track: Takeaways for Every Ride
While this project focused on redesigning a seat shell for a high-profile brand, its core principles are broadly applicable. The fundamental challenge of balancing competing objectives—like shock absorption, ergonomics, and cost—is common in any off-road vehicle seat design. Achieving one result, such as better shock absorption, can sometimes compromise another, like ergonomic geometry.
This project proves that innovative component redesign can create wins for everyone. The OEM benefits from part consolidation and cost savings, strengthening their bottom line. The end customer enjoys a more comfortable ride and a stronger, more reliable vehicle. Formerra’s role as a collaborative partner, providing deep technical expertise, simplifies these complex projects and helps our clients deliver exceptional products.
Want to see how Formerra fuels innovation across the outdoor and powersports industries?
Explore more real-world success stories in our Outdoor and Powersports Success Guide and discover how our materials expertise, technical support, and supply chain solutions help OEMs overcome even the toughest design and engineering challenges.
Check out the Outdoor and Powersports Success Guide to learn more.
