How classy is that?!? Driving in a car that integrates 3D printed race seats made by Porsche.  Car connoisseurs know that most racing seats are made of carbon fiber which is awesome given the material’s ability to deliver lightweight and strength to parts. In order to enhance the fabrication process of seats, Porsche has decided to leverage additive manufacturing rather than moulds, as traditionally done.

Let me remind you that this is not Porsche’s first experience with AM. The automaker recently 3D printed an E-Drive housing in just 21 hours and had already leveraged Additive Manufacturing Design freedom for new bucket seats.

As far as this 3D-print bodyform full bucket seat is concerned, a select group of Porsche drivers is already testing it.

“Seats adapted to individual drivers have been available for a long time in professional motorsport. Now Porsche also offers a road-approved customization with different rigidity grades as standard,” says Porsche test driver Lars Kern. “During the initial test drives, I was impressed by the ergonomics – the slightly lower seat position and improved thigh support are similar to what you get from the seat in a racing car. The passive ventilation is impressive too.” Compared to conventional full bucket seats, the new seat is also more than eight percent lighter.

 The manufacturing process

The 3D-print bodyform full bucket seat will be integrated in the Mission R, an all-electric GT racing car which embodies Porsche’s vision for how customer motorsport could look in the future.

The manufacturing process of the 3D-print bodyform full bucket seat is based on Porsche’s lightweight full bucket seat. It features a sandwich construction where a base support made from expanded polypropylene (EPP) is bonded to a breathable comfort layer consisting of a mixture of polyurethane-based materials made using additive manufacturing – in other words using a 3D printer. The components are clipped together. This innovative joining technology means that the seat generates no emissions associated with adhesives.

The outer skin of the seat is made of Race-Tex. This non-slip material offers plenty of support in the seat and the unique perforated surface enables improved passive ventilation.

Window panels show exposed, full-color sections of the 3D-printed lattice structure and give the full bucket seat an unmistakable design. Initially, customers can choose between Black, Guards Red and Racing Yellow for these design elements. In February, Arctic Grey, Ultramarine and Shark Blue will be added to the color range. Porsche is planning another customization for the medium term: 3D-print bodyform full bucket seats adapted to the individual body contours of each customer.

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