Grammer AG, Lantal Textiles AG, N+P Innovation Design, and SEKISUI KYDEX bring the innovative Nordstern seating concept to life for rail interiors. 

Workshops can bring industry leaders together, guiding them to innovative collaborations, solutions, and concepts that speed train interiors toward an elevated passenger experience.

The Nordstern seating concept is one such example of bringing disruption to the rail interiors industry through innovation and collaboration.

THE IMPORTANCE OF EARLY PARTNERSHIPS

After the first RedCabin Railway Interior Innovation Summit, held virtually in December 2020 due to the pandemic, N+P and SEKISUI KYDEX started working together remotely to bring N+P's rail designs to life. With an aim to establish an iconic presence in the market while considering the various parameters, N+P began utilizing KYDEX^® Thermoplastics and the thermoplastic manufacturer's Crystal Cabin award-winning Infused Imaging^™ technology within their designs. This initial partnership eventually led to a pioneering rail collaboration just a few years later. Karyn McAlphin, Creative Design Lead for SEKISUI KYDEX, noted, "Building trust with like-minded companies not only opens the door to future projects but also allows you to achieve remarkable results in a shorter timeframe. We often stress the importance of early partnerships and were delighted to start this partnership early on with N+P.”

WHERE THE INNOVATION BEGAN

Nearly one year later, in October 2021, N+P and Grammer conducted a workshop to identify opportunities for improvement within seating solutions. This collaboration led the two to develop a "Blue Ocean Strategy," a business approach developed by professors W. Chan Kim and Renee Mauborgne. This strategy focuses on creating a new market space or industry instead of competing in an existing market with other companies (known as a "Red Ocean").

Usually, companies compete in a "Red Ocean," where they try to outperform each other in an existing market space, leading to intense competition, price wars, and limited growth opportunities. On the other hand, a "Blue Ocean" represents an unexplored market space with little or no competition. Businesses that seek to implement a "Blue Ocean Strategy" focus on innovation, value creation, and differentiation. This can involve creating new products or services, redefining existing ones, or finding new ways to meet customer needs.

The objective is to stand out in a way that attracts new customers and allows the company to set its terms without being constrained by existing market norms. For Grammer and N+P, this strategy was implemented through the idea of creating a new seating concept that embodies Grammer’s design language across the entire product line, with attention to even the smallest detail, ensuring the passenger experience is never compromised.

To distinguish themselves in the market while elevating the passenger experience and delivering enhanced aesthetics, N+P knew it would take multiple collaborative partners to achieve this never-before-seen concept. Recognizing the significant potential in leveraging state-of-the-art materials to achieve the goal, Christiane Bausback, Managing Director for N+P Innovation Design, introduced Grammer and SEKISUI KYDEX at the RedCabin Railway Interior Innovation Summit held in Washington, D.C in 2022. "Partner selection was a large part of creating a holistic solution,” stated Bausback. “We believed the right partners could make a significant difference, bringing the design to life by translating patterns and design DNA from one supplier to the other while keeping the philosophy.”

Using N+P's evaluation toolkit, the new Nordstern seating concept was presented for the first time to selected operators and OEMs at InnoTrans 2022. The original design concept received a positive response from stakeholders, and Grammer and N+P obtained crucial feedback to enhance the concept even further.

Prior to the 2023 RedCabin Railway Interior Innovation Summit in Salt Lake City, Grammer began construction of the S-Seat prototype while working with N+P on the feedback from InnoTrans to optimize and evaluate the concept internally. In addition, they developed an app prototype that connects to the Nordstern S-Seat and provides customers with a unique and fully customizable experience.

DISRUPTION MEETS COLLABORATION

While each partner brought their own distinctive contributions, N+P played a crucial role in coordinating the various disciplines to create a promising solution for the future of rail interiors. With N+P’s familiarity with Lantal's unique and fully customizable MESH seat fabric and their past work with SEKISUI KYDEX, N+P identified Lantal Textiles and KYDEX^® Thermoplastics as ideal sustainable material finishes for the Nordstern seating concept. Utilizing the material finishes to achieve a common gradient pattern across hard and soft materials poses an exciting and aesthetically pleasing look that the operator can easily customize.

Shortly after the 2023 RedCabin Railway Interior Innovation Summit, Grammer, N+P, Lantal, and SEKISUI KYDEX began collaborating on the groundbreaking new seating concept. Work quickly began between the partners, and within just six months, the four partners developed and unveiled the design prototype, showcasing it at the November 2023 RedCabin Railway Interior Innovation Summit in Vienna. “Typical projects can take well over a year from the idea conception to the final project. However, through this open collaboration, we were able to create a first-of-a-kind seat within months,” said Stefan Wilhelm, Lantal's Head of Markets Ground.

SOLVING FOR PAIN POINTS

Rapid lead times can sometimes create pain points, which can lead to missed timelines or underdelivered promises. In this case, while the team was able to integrate advanced technology into the seat construction, select the Lantal yarn colour, determine the KYDEX^® 2200LT material placements, approve the Infused Imaging^™ designs, and construct the seat within just six months, some challenges soon emerged. Transitioning from the knitted textile pattern to a 2-dimensional thermoplastic that could be thermoformed into a 3-dimensional shape without altering the pattern's design took some time to work through initially. In addition, SEKISUI KYDEX not only needed to match the varnished color directly next to the thermoplastic, but they also needed to match Lantal's yarn colour as it had already been dyed to the specifications provided by N+P. To avoid delays in unveiling the Nordstern seating concept, the SEKISUI KYDEX designLab^® and appLab^™ teams were brought in to assist.

In late October 2023, the partners from Grammer, Lantal, and N+P met with designLab^® and appLab™ teams via video conference call for their help in solving a shade variation issue encountered during the initial thermoforming process used for the previously approved master. The designLab^® and appLab^™ teams were given two weeks to complete the project – a process which would normally require four months. Without adjacent materials to determine how the materials would look in a real-world environment. The teams quickly began making modifications and running test trials. According to Elijah Peltz, appLab^™ Specialist for SEKISUI KYDEX, "Typically, we do not aim to match colours with Infused Imaging^™ parts during the forming process; however, the appLab^™ team was brought in to help reevaluate the colours and make new parts in time for the unveiling."

To match the correct colour and meet the timeframe, designLab^® and appLab^™ produced five different parts with five variations of colour, and another twelve parts with additional colour variations and Infused Imaging^™ artwork. As the Infused Imaging^™ artwork was intended for specific placement on the Nordstern seatback, the team had to ensure the colour matched and the artwork was correctly positioned. Becky Gallup, CMF Design Manager for SEKISUI KYDEX, noted, “By bringing the project in-house and utilizing the designLab^® and appLab^™ resources, we were able to make multiple iterations to quickly find the perfect mold and form, thereby addressing the colour variation and distortion issues.”

Bringing the project in-house to the appLab^™ team allowed for a quicker resolution. Additionally, they were able to document the steps required to create a perfect part. For any typical prototype project, the appLab^™ performs all the troubleshooting in-house. They begin scaling up the artwork on the tool, and once the mold or formed part is completed, they transfer the knowledge to support the OEM’s chosen thermoformers. This is done via presentation or by going to the thermoformers in person with the necessary tools to demonstrate. Erin Connelly, Sr. Applications Engineer for SEKISUI KYDEX, explained, “In this case, we ran extra grid sheets, which we will send to the thermoformer, to duplicate the sheets made here onto the tooling they made. This allowed us to see the difference between their tool and our tools and ultimately provide the information needed to make the adjustments to the Infused Imaging^™ designs.”

HOW THE INNOVATIVE DESIGN WORKS

By embracing technology to enhance the overall passenger experience, Nordstern's real-time personalized trip connectivity offers a cutting-edge interface with a customized experience. The system enables passengers to check in, adjust seats, select entertainment options, and receive travel updates—all from the comfort of their seat. By using KYDEX^® material featuring a bespoke Infused Imaging^™ woodgrain pattern on the tiered tray tables, as well as the console design – complete with a wireless charging symbol, Grammer was able to integrate inductive charging stylishly and seamlessly into the Nordstern seat.

Timo Bauer, Grammer's Vice President of PMS Rail & Road, stated, "When we step onto a high-speed train, we all hope for a warm and inviting atmosphere. The Nordstern interior experience, based on Grammer's modular magnesium seat structure and our partnership with N+P, Lantal, and SEKISUI KYDEX, offers a range of seat configurations, delivering increased comfort, privacy, and safety—all within the same space as traditional cabins. These seats are designed to make public transportation more appealing, offering a unique and adaptable journey." With advanced technology and durable, sustainable materials, Nordstern’s adaptable seating concept ensures that train interiors can be transformed into welcoming, modern, and environmentally friendly spaces.

DESIGNING FOR SUSTAINABLE DISRUPTION

Sustainability was not only a crucial component in material selection but is also becoming an increased requirement within the rail industry. While both suppliers brought sustainable solutions to N+P’s innovative design, they also contributed an elegant design methodology to minimize weight while maximizing the design and functionality. The Nordstern seating concept incorporates Lantal’s fully recyclable seating fabric and durable and recyclable KYDEX^® Thermoplastics, significantly reducing weight over standard industry materials. Ruben Bake, Mass Transit Business Manager for SEKISUI KYDEX, noted, "Sustainable design is sometimes tricky for organizations to understand, so we were delighted to engage our designLab^® and appLab^™ Innovation Centers in a project to enhance the customer experience in an environmentally responsible manner."

Lantal's 100% polyester MESH seat covers promote sustainability with easy recyclability and low maintenance while enhancing passenger comfort with its breathable fiber composition. According to Wilhelm, "The fiber composition of Lantal's new MESH seat covers provide excellent moisture absorption and breathability to enhance the passenger experience while offering the highest possible durability. With significant weight savings and a 100% recyclable material, the MESH seat covers contribute to the sustainable development requirement from Grammer and N+P." Lantal's MESH seat covers provided Grammer and N+P with the design freedom they required while delivering the comfort the passenger deserved.

RECOGNIZING INNOVATIVE DESIGN

In this vision of modern train travel, passengers can enjoy an unparalleled combination of comfort, technology, and sustainability, all without compromising design. During the 2023 Red Cabin Railway Interior Innovation Summit held in Vienna, Grammer, Lantal, N+P, and SEKISUI KYDEX received the prestigious RedCabin Rail Interiors Award for Design Innovation of the Year for the Nordstern seating concept. This collaboration between the four partners is speeding rail into a new era that enhances overall passenger satisfaction with a world of comfort and connectivity, all while utilizing beautiful and sustainable materials.

Grammer's configurable Nordstern seating concept is not only elevating the future of train interiors but challenging the rail industry to adopt a new path based on its Blue Ocean strategy.

Pictured: Stefan Wilhelm, Head of Markets Ground for LANTAL Textiles, Sebastian Wegmann, Business Development Manager Rail and Bus for Grammer AG. Ruben Bake, Mass Transit Market Business Manager, SEKISUI KYDEX, Christiane Bausback, Managing Director for N+P Innovation Design GmbH, and Timo Bauer, Vice President of PMS Rail & Road for Grammer AG.

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The rolling stock industry is growing worldwide due to sustainability concerns. Beyond being a viable alternative to automotive and aviation travel, depending upon stage length, the rail industry is poised to become more sustainable through the material selection process. As a replacement to fiberglass reinforced plastic (FRP), thermoplastics can transform rail car interiors to be more lightweight and durable, with added design forward options to improve the passenger experience.

The mass transit interiors team at SEKISUI KYDEX set out to showcase how thermoplastics can provide better aesthetics, enhanced durability, and improved sustainability for rolling stock interiors. To do this, the designLab^®, appLab™, and business development teams collaborated to create a pressure formed sample using polyvinylidene difluoride (PVDF) capped KYDEX^® 2200LT rail material with Infused Imaging™. The goal was to develop a part to debut in September 2022 at InnoTrans, the world’s largest trade fair focused on the rail transport industry. Meeting this deadline required a quick turnaround by rapidly prototyping the parts.

PART DEVELOPMENT

In June of 2022, SEKISUI KYDEX welcomed their summer appLab™ interns from the Pennsylvania College of Technology, Plastics and Polymers program. Students primarily focused on creating and designing parts. The mass transit prototype project offered an opportunity to educate the interns on the rapid prototyping process, while creating an educational tool for customers to illustrate different thermoforming processes within one part.

To kick off the project, a competition was held among the interns to design and present mass transit inspired parts for consideration. They were tasked with developing a part that included both a positive and negative mold shape in one tool, allowing dual use of the part by simply flipping the sheet in the thermoforming process. When thermoforming within the positive side of the mold, the corners are more rounded, and when pressure forming the negative side you can achieve crisp edges.

“Our internships give students the opportunity to work on real projects as part of the learning process. This project is an excellent way for our interns to get hands on experience in the field in which they are interested, while providing an educational tool for use with customers. The final part serves as an example of how KYDEX^® Thermoplastics perform in different thermoforming processes,” said Shawn Gum, Business Development Engineer.

Elijah Peltz’s concept for a mini seatback design with the KYDEX^® Thermoplastics logo was ultimately chosen. He spent July 2022 refining the design and programming the tool path on the CNC machine. During his experienceship, Peltz learned to program design for both RenShape^® and aluminum tools. Ideally the final tool would be made from aluminum because the molds are temperature controlled and provide better consistency from part to part. They are also more durable and can be used for thousands of parts. RenShape^® is an inexpensive polyurethane modeling and styling board that can be quickly and easily CNC routed into specific shapes but is not temperature controlled. Although the temperature of the RenShape^® mold can fluctuate over time and the part dimensions can vary from part to part, it is ideal for rapid prototyping.

Originally Peltz planned to create the first tool using RenShape^® because of how quickly it can be developed, but machine time was limited due to other appLab™ projects. Peltz then focused on developing an aluminum tool and learning how to run the machine efficiently. In collaboration with Collin Everett, appLab™ Specialist, who has a background in machining, they implemented faster feeds and speeds to expedite the rapid prototyping and learning process. Peltz’s internship ended in early August 2022 with a nearly complete aluminum tool.

“The seatback project was a fun challenge because I had never machined something that complicated. It’s still hard to believe I executed a detailed project on a machine I had just learned how to use. I was impressed by the results for my first try despite it still needing some cleanup work,” said Peltz.

To ensure first round parts for the InnoTrans Summit in September, Shawn Gum, Business Development Engineer, stepped in to expedite a positive RenShape^® tool with an in-house trim fixture in less than two days. The parts pulled from this round were not as crisp as the final but were excellent talking pieces for the InnoTrans Summit.

“Several seat manufacturers I visited at InnoTrans were impressed with the design capabilities of the thermoformed mini seatback. They were particularly interested in the patterned samples as great alternatives to laminates. They also provided us with some pattern direction which we were able to implement in our next round of samples,” said Ruben Bake, Mass Transit Business Manager.

With the first parts out the door, Everett stepped in to finalize the aluminum tool in less than two months. He machined air pockets and drilled holes on the back side of the tool to ensure consistent thickness from the textured surface of the tool to easily drill the vacuum holes, then sanded and polished the surfaces. Mounting holes were added to allow the final tool to be bolted to a universal temperature-controlled plate, which makes switching out tools on the thermoformer more efficient. Once the tool was ready, the appLab™ team sent it to Custom Etch to add a light sand finish surface texture, which was completed in less than one week. This texture is similar to KYDEX^® Thermoplastic’s standard P3 texture, but slightly deeper so when pressure formed it mirrors how P3 texture looks on flat sheet.

With the finalized tool back in hand, the appLab™ and maintenance teams drilled in vacuum forming holes and constructed the pressure box for the thermoformer. The team then pressure formed a full set of positive and negative parts using the textured tool in time for the RedCabin Railway Interiors Innovation Summit on November 15, 2022.

MATERIAL PROCESSING CONDITIONS

After pulling multiple parts and adjusting the MAAC thermoformer conditions, the appLab™ team found 390 degrees Fahrenheit with a bottom heat of 10% and top heat of 60% yielded the ideal draw results.

MATERIAL DESIGN

While the appLab™ team was working on tool design, the designLab^® team was developing patterns and selecting colours for the final parts. Their goal was to showcase the benefits of integral colour and Infused Imaging™ technology utilizing PVDF capped materials, compared to metal or fiberglass that is traditionally painted.

“One of the greatest benefits of using Infused Imaging™ on capped KYDEX^® Thermoplastics is that customers can create custom panels with orders as low as one sheet. Traditionally, capped materials with a pattern require purchasing an entire roll of patterned film,” said Karyn McAlphin, Creative Design Lead. She continued, “If you’re already placing an order for a specific-coloured substrate – pale grey or beige for example – you can easily develop a complementary pattern that can be infused onto just a sheet or two for those special areas in your interior.”

Infused Imaging™ technology embeds the pattern into the sheet, rather than on it, allowing custom quantities and increased quality. Importantly, it won’t chip, fade, or delaminate like other materials, and because the design permeates the capped material, it retains the anti-graffiti and cleanability properties of the PVDF film.

For the first round of parts, Becky Gallup, Senior CMF Design Artist, and McAlphin discussed using a tiny, tight geometric design from the 2022 Infused Imaging™ collection. Their objective was to illustrate how a pattern could be used to create the illusion of solid-coloured seats throughout an entire train car yet provide greater visual interest up close to enhance the passenger experience.

To do this, Gallup recreated the Geo pattern to work with the part. By turning the pattern 45 degrees and adjusting the scale to complement part geometry, she was able to accommodate the alignment of the pattern into the KYDEX® logo that was formed in the part.

To ensure sustainable practices throughout the project, the team opted to utilize material running in an existing order of solid colour sheets of material with the PVDF film. Because the material was a bright warm cream colour with a yellow undertone, and the team wanted a more neutral design, Gallup used Photoshop overlays to adjust the pattern with colour variations and colour intensity across one image. The image was run through the Infused Imaging™ process and the team reviewed the colour, clarity, and intensity levels to select the right mix. “You need to find the sweet spot between colour and pattern so it’s not overwhelming. A colour that’s too intense can result in too much contrast and detract from the overall part design”. She continued, “On the other hand, a pattern that is too subtle can lose its visual intrigue on the final part.”

Gallup was able to reduce the warmth of the substrate and transform the pattern direction to complement the integral colour of the stock sheet as well as the geometries of the final part. “These subtle changes show how versatile Infused Imaging™ designs can be across multiple applications,” stated Gallup.

For the second round, McAlphin and Gallup selected a pale woodgrain pattern consistent with recent trends in railcar interiors to show how fluid patterns can seamlessly transition over part corners and draw depths. Gallup said, “The woodgrain has a natural wave in the pattern which we successfully integrated into the part when it was formed. With this more intricate design, we could capture pattern detail without overpowering the final part’s shape.”

The base colour for the woodgrain was a more subtle and cool beige compared to the first sample, and Gallup selected an Olive Ash design. She adjusted several darker areas of the woodgrain by modifying the grain colour directly and changing the placement of the grain to the part, to enhance the appearance of a modern wood design. She then also edited the scale of the woodgrain to match a full-size seat so customers would be able to visualize the pattern in a true to life application scale.

Utilizing rapid prototyping and industry leading design, the teams at SEKISUI KYDEX delivered on their mission to create a versatile and educational part for the Mass Transit Industry. The team is already back to work on the next round of pattern design iterations to showcase even greater possibilities.

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With multiple patients being evaluated using durable medical devices like MRI machines on a daily basis, keeping equipment clean is an important part of keeping patients healthy. Product compatibility between these disinfectants and the materials used on the medical device surfaces are critical.

In November 2019, a simple sample request between PDI and SEKISUI KYDEX, two leading manufacturers for the medical community, evolved into a testing opportunity to demonstrate the efficacy of PDI disinfectants and KYDEX® Thermoplastics.

PDI is a global leader in the fight against preventable infections. It is their goal to manufacture disinfectants that are strong enough to eliminate harmful bacteria, yet gentle enough to preserve the integrity of the medical devices that are being disinfected.

SEKISUI KYDEX innovates and creates sustainable thermoplastic material solutions for the next generation of product design. KYDEX® Thermoplastics are durable, chemical resistant, inherently antimicrobial, and will not be stained by harsh cleaning agents, making them ideal for medical devices.

“For years, PDI has been innovating its disinfecting product line to ensure we continue to provide products that meet today’s clinical efficacy needs, yet are gentle enough to preserve the integrity of the medical devices being disinfected,” said Candice Taylor, Senior Director Product Development. She continued, “Our collaboration with SEKISUI KYDEX for testing has helped ensure we are collectively building compatibility into the development process, ultimately helping healthcare facilities maintain the physical integrity of the medical device that are disinfected and reducing the risk of infection transmission.”

THERMOPLASTIC AND DISINFECTANT COMPATIBILITY

Many plastics used for medical devices suffer from environmental stress cracking from exposure to healthcare-grade disinfectants. Plastic degradation can lead to loss of device function and eventually complete device failure. Understanding thermoplastic limits of chemical resistance to healthcare grade disinfectants is a critical step in material selection by design engineers to ensure medical devices meet their intended product service life.

PDI and SEKISUI KYDEX set out to test the possible degradation of KYDEX® Thermoplastics when exposed to PDI medical-grade disinfectants. Testing completed by both PDI and SEKISUI KYDEX labs revealed that KYDEX® Thermoplastics hold up to PDI disinfection products with over 90% mechanical property retention when tested to the ASTM-D543 standard.

Extensive testing was done using the ASTM-D543-20, a globally recognized standard practice for evaluating the resistance of plastics to chemical reagents. Materials were tested using both immersion testing and reagent exposure testing. Weight, dimension changes, and mechanical properties were evaluated for material degradation.

To perform the initial testing, CNC routed KYDEX® thermoplastics tensile bars were used. Thermoplastic products tested included KYDEX® T, 100, 110, 430. Thermoplastics were exposed to Sani-HyPerCide^TM, Sani-24®, Super Sani-Cloth®, Sani-Cloth® Prime, Sani- Cloth® Bleach, Sani-Cloth® AF3 disinfectants from PDI.

“What better way to prove how our products hold up to the chemical disinfection process than by collaborating with PDI, an industry leader in healthcare wipes? Recognized for their Sani-Cloth® brand, they are a household name in the healthcare industry,” says Mark Denning, SEKISUI KYDEX Medical Market Business Manager. “They are a great industry leader to partner with on our current and future product offerings.”

ENVIRONMENTAL STRESS CRACKING

Environmental stress cracking testing was guided by ASTM-D543. KYDEX® Thermoplastic tensile bars were placed in the strain jig at 1.5% nominal strain. The tensile bars were exposed to PDI disinfectant wipes for 48 hours, at 24-hour intervals the wipes were reapplied. The tensile bars were removed from the jig and allowed to relax for 1hr or greater. These tensile bar sets were later used to evaluate changes in the material’s tensile properties. A more rigorous set of tests were conducted by extending the exposure periods. SEKISUI KYDEX extended the exposure testing to a full 28 days, in an effort to force a material failure.

MECHANICAL PROPERTY RETENTION

The KYDEX® Thermoplastics tensile bars were removed from the stain jigs after the 48 hour exposure period and one-hour relaxation period to be tested for changes in mechanical properties. Specifically, the bars were tested for changes in tensile stress at yield by via a mechanical tester. Tensile testing was guided by ASTM-D638. Mechanical retention, the quotient of tensile stress at yield for exposed samples compared to the tensile stress at yield for unexposed samples, was calculated. An acceptable test result is 70% mechanical property retention. KYDEX® Thermoplastics retained greater than 90% of its mechanical properties when exposed to PDI germicidal disinfectants.

IMMERSION OBSERVATIONS

Immersion testing measures weight and dimension changes to the thermoplastics when exposed to PDI disinfectants. The test takes a 2” by 2” square submerged in the solution for up to 128 hours, stirring every 24 hours. The material is observed for loss of gloss, developed texture, decomposition, discoloration, swelling, clouding, tackiness, rubberiness, crazing, bubbling, cracking, or solubility.

FUTURE PRODUCT COMPATIBILITY

As a result of the changing landscape for chemical technologies and medical device engineering as a result of the COVID-19 pandemic, PDI and SEKISUI KYDEX are expanding their testing for product compatibility. Currently, testing has evolved to include geometric and formed parts, and new chemical consistencies and technologies. PDI recently acquired Tru-D® SmartUVC, a pioneer in the UVC disinfection industry, and maker of the first UVC robot.

Along with SEKISUI KYDEX, they have begun testing this new disinfection technology with KYDEX® Thermoplastic material, with results expected over the next few months. Additional testing using PDI medical-grade disinfectants will be done on Infused Imaging™ Technology and KYDEX® Injection Molding Resins.

“PDI’s expertise in disinfection and material testing has been a great compliment to the research of our appLab™. With their focus on expanding into other disinfection technologies, such as UV-C, they have obvious plans to stay at the forefront of their industry’s solutions.

“Working with a leader like PDI can help SEKISUI KYDEX understand the future trends of disinfection and what challenges the industry will be facing,” Denning said.

The combination of the efficacy of PDI disinfectants and the durability and chemical resistance of KYDEX® Thermoplastics means that clinicians and medical device designers can rest assured that device design and infection prevention are optimized through this compelling and unique collaboration.

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The Company

Proterra® was founded in 2004 by entrepreneur Dale Hill. He believed Proterra could lead the industry by combining innovations in high-performance electric propulsion with lightweight interior and exterior design. Hill assembled a team of engineers that began working to revolutionize mass transit by creating a new alternative: a 100% battery-electric bus.

The Challenges

Proterra’s goal was to design an all-electric drivetrain powerful enough to move a fully occupied bus through city traffic. In addition, the battery had to have enough energy storage capacity to be able to travel significant distances between battery recharges. The bus had to be both cost-effective and efficient, with competitive pricing and low operating costs.

Beyond the engine, design materials needed to be lightweight for greater efficiency and range; attractive, for passenger appeal; and durable, to reduce replacement costs. Further, materials would have to meet transportation industry safety standards and be produced in a way that worked with Proterra’s supply chain requirements.

The Solution

Proterra’s all-electric buses use KYDEX® 6200, KYDEX® T, and ALLEN® 5160WHG for internal and external applications. These lightweight materials significantly reduce weight versus more traditional materials, such as fiber-reinforced resins or metal, thereby increasing vehicle efficiency and range. At the same time, these materials provided a range of texture and colour options that were refined to maximize colour stability under UV exposure. The materials are also recyclable and therefore contribute to a better, more sustainable environment. In addition, all materials meet Motor Vehicle Safety Standards, and KYDEX® 6200 is compliant with Docket 90, a set of test procedures intended to assess not only flammability but also smoke emission characteristics. SEKISUI KYDEX’s rapid order fulfillment helps Proterra keep its supply chain running smoothly.

SEKISUI KYDEX’s relationship with Proterra is defined by collaboration and technical support. Using designLab®, Proterra leveraged KYDEX’s mass transit experience and thermoformer relationships to make highly-informed decisions about material, colour, and finish.

Results

SEKISUI KYDEX’s lightweight materials help Proterra` vehicles work more efficiently, producing zero tailpipe emissions, versus the 229,167 pounds of CO2 emissions produced annually by a standard diesel bus. Using SEKISUI KYDEX’s high-quality, lightweight, recyclable materials, Proterra has created the best zero-emission alternative to traditional steel buses.

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RedCabin brings industry leaders together to innovate for the future passenger experience in an aircraft cabin.

The BUTTERFLY® 2.0 Seating project is a perfect example of bringing disruptive ideas to the aviation interiors market with partners Butterfly Flexible Seating Solutions, TAPIS, MGR Foamtex, Studio Catherine Barber and SEKISUI KYDEX.

AN INDUSTRY LEADING PARTNERSHIP

BUTTERFLY® is a flexible seating solution that allows instant transformation between premium economy/ regional business class, and long-haul flatbed suites. Lars Rinne, BUTTERFLY® Co-Founder and Commercial Director and James Lee, Co-Founder and Creative Director began their journey in 2014 after winning the highly coveted Crystal Cabin Award with the initial design of the concept.

In 2019, after spending two years traveling the globe collecting customer feedback with full-size mockups of the concept, they were ready to take BUTTERFLY® to the next level: to build an enhanced version of their prototype featuring flight ready materials, structure, and design.

During the December 2019 Red Cabin Aircraft Cabin Innovation Summit, Rinne met industry leaders and developed partnerships to achieve the goals of an enhanced prototype. Their partnership was announced at the end of the event.

“With our partners’ know-how, we can put BUTTERFLY® in the position to be competitive with both standard recliners as well as business class lie-flat suites. We are in the process of creating a seat that we are happy to sell, airlines are thrilled to buy, and passengers are delighted to sit in,” said Rinne.

This sparked the beginning of a journey through the SEKISUI KYDEX appLab™ and designLab® Innovation Centers, where engineering and design meet.

WHERE INNOVATION BEGINS

Rinne and Lee visited the appLab™ innovation center to explore thermoplastics. They were introduced to the material differences and capabilities, processing options, and how to design parts for manufacturing. The unique and flexible design of BUTTERFLY® 2.0 requires customization of each part of the seat. With a design more complicated than a traditional seat, both BUTTERFLY® and the appLab™ were up for the challenge.

SEKISUI KYDEX developed their Innovation Centers, as a place to explore the possibilities. To inspire their visitors, every interaction is curated to help customers reach their goals. These service areas are not just focused on products and process but are instead designed for paths of discovery and exploration. While innovative solutions are expected to come from these Innovation Centers, the focus is on the experience of creating them rather than finding one specific solution.

“Some who visit SEKISUI KYDEX come for design and others come for engineering, the two tenets of the designLab® and appLab™ Innovation Centers. But in every visit, there is the unknown, discovered as everyone collaborates. Our teams learn from our visitors as much as our visitors learn from us. All that’s needed is curiosity,” said Bernadette Chupela, Customer Experience Manager at SEKISUI KYDEX.

The first step in the BUTTERFLY® 2.0 project partnership was to bring James Lee from BUTTERFLY®, Catherine Barber, Owner of Studio Catherine Barber, Jason Estes, Vice President of Global Sales & Marketing for Tapis and SEKISUI KYDEX to the table for 3 days of innovation, design, and exploration.

“We are excited to help innovative startups like BUTTERFLY® bring their disruptive ideas into the market,” says Ronn Cort, President and COO of SEKISUI KYDEX, speaking at Red Cabin’s Aircraft Cabin Innovation Summit in London. “That’s the mission of our appLab™, an innovation center where ‘what ifs?’ become fully-fledged projects.”

THE DESIGNLAB® EXPERIENCE

Starting in the designLab®, Barber and Lee presented their CMF design ideas to kick off the collaboration. They shared inspiration of earth tones found in textiles, architecture, and bespoke environments. Estes provided stacks of textiles in a range of textures and hues for comparison.

Taking the colours of the textiles and the CMF inspiration boards, the designLab color technicians create a range of colour iterations for consideration.

Teams enter a state of flow as the project progresses. Ideas bounce around conference rooms where sketches, swatches, and phrases cover the whiteboards.

Pieces of fabric, thermoplastics, and timelines float on moving bulletin boards, visualizations of a project taking shape. Everything a design team needs is at their fingertips, from advanced equipment, to the physical and mental space to innovate, which sometimes creates “happy accidents.”

“That’s the joy of it, those happy accidents would not happen otherwise. It’s that magical element. It’s easier to be bold when you’re here. If I send you a written brief, I’m really conscious. I don’t want you making endless iterations that won’t work because of my brief. I feel a real responsibility to limit that sampling to be very carefully targeted. But if I’m here with you, we can negotiate. ‘Can we try that?’ or ‘Do we have time?’ become questions that can be asked and answered quickly, moving the project forward in creative ways,” said Barber.

Being on-site also allowed the team to explore ways of using Infused Imaging™. Infused Imaging™ technology is a Crystal Cabin Award winning, proprietary process that embeds imagery into thermoplastic material. Designers, seat manufacturers, and airlines can create bespoke environments using colour, images, and texture without sacrificing strength and durability.

Part of Barbers inspiration featured designs found in architecture. SEKISUI KYDEX Senior Graphic Artist, Becky Gallup digitized the inspiration and worked with Barber to test iterations of the design in real time. During the three day period, Gallup took Barber’s feedback and modified design colours, overlayed multiple visual textures, and explored design direction.

Because they were able to design, produce sheet, and thermoform the material all in house, Barber could see how the iterations performed and choose the best one for her vision. Usually designers must traverse the universe through trips to the customer, textile house, materials manufacturer, seat OEM, and more.

Materials and creative briefs are sent all over the world and can end with forcing a designer to settle or asking suppliers to send more options.

“The Innovation Centers (appLab™ and designLab®) accelerated the trim and finish selection process with space to truly collaborate on this project together with our partners. Without these resources, this project would have taken weeks instead of hours. I was amazed at how quickly the team incorporated feedback to develop the samples. Having these tools and resources allowed us to put the final touches on the CMF process for BUTTERFLY® 2.0 Seat,” said Estes.

Part of what made this project successful, was the team’s preparation for virtual collaboration following their departure. Utilizing the X-Rite Total Appearance Capture System (TAC™), the team scanned in materials of interest and loaded digital renderings of BUTTERFLY® 2.0.

This allowed the team to use KeyShot® to digitally apply materials, textures and colours after the visit concluded. While colour, materials and finish were being explored in the designLab®, Lee and the team were exploring part geometries and thermoforming in the appLab™. They were preparing for the appLab™ to create more than 30 parts for the final prototype from Lee’s designs.

THE APPLAB™ EXPERIENCE

Lee had already spent some time with the appLab™ and was informed on thermoplastics. During this second visit, Lee and the team looked at individual part geometries to discuss how the parts would connect and perform. The appLab™ engineers made recommendations on where pressure forming would be better than vacuum forming and provided modifications to the part geometries to adjust undercuts, split lines, and hidden edges.

The part design was unique because, compared to a traditional seat, the BUTTERFLY® suite is designed for multiple seat configurations.

To accommodate the variety of shapes and functionality of the suite, over 30 thermoplastics parts would be required.

“Being able to design a part in CAD, mill the tooling by CNC, and seeing it thermoformed right in front of my From Left to Right: Shawn Gum, Lars Rinne, and James Lee eyes, all in the same place and on the same day really helped me as an industrial designer to understand the capabilities and limitations of vacuum and pressure forming. It enabled me to design parts that are more optimized and cost-efficient.” said Lee.

Much of the appLab™ experience then transitioned to virtual collaboration. Lee continued to perfect the parts designs.

SEKISUI KYDEX worked with partners Orange Packaging and Catalysis Additive Tooling to make the part molds.

It is through relationships with partners like Catalysis that can 3D print molds that SEKISUI KYDEX was able to move quickly with parts arriving in under 48 hours.

While the molds were being produced, Shawn Gum, Applications Engineer, SEKISUI KYDEX, made the wooden frame to retrofit the parts. Lee provided engineering drawings for the aluminum frame that would ultimately be used in the final prototype. Gum used these drawings to duplicate a frame out of wood meeting the incredible short lead time required.

“We used the engineering drawings provided to create 3D part models to assemble the frame. These parts were cut using our Thermwood 5-axis CNC router. The CNC cut very accurate parts for the frame to ensure our formed parts fit as they were intended to. There were many parts with overlapping joints and our frame allowed us to confirm they fit properly, and the joints lined up.” said Gum. “With the aggressive timeline the parts had to fit correctly to avoid losing time shipping parts back and forth. By actively collaborating with the BUTTERFLY® team we were able to produce many different parts within a short period of time.”

Once the molds were received, the appLab™ engineers formed each KYDEX® Thermoplastic part for the prototype. These parts were then trimmed using a CNC router.

The appLab™ engineers inspected each part and worked to retrofit them to the wooden frame. Because there were so many intricate and unique parts for the design, it was important that the team have a frame to test part fit on. Because the frame was made from wood and was just a test frame, the holes for part mounting were not in the frame. This meant retrofitting the parts would require taping parts to the frame for fit adjustment. By retrofitting them in-house, they could make adjustments to the parts before sending them to BUTTERFLY®.

Once the appLab™ team confirmed the parts were accurate, they shipped them to BUTTERFLY® to be added to the final prototype. BUTTERFLY® had their aluminum frame ready and retrofitted the parts for their final prototype. Because this frame was more accurate, they were able to locate the areas where part adjustment was required. This was minimal as the appLab™ had been able to identify some of these potential inconsistencies with the use of their wooden frame.

THE FUTURE OF BUTTERFLY® 2.0 AND KYDEX® THERMOPLASTICS

All of this work, from design to construction, was done between December 2019 and March 2020, giving meaning to the phrase ‘rapid prototyping’. The goal was to launch the seat at the 2020 AIX Expo. Unfortunately, the COVID-19 Pandemic hit in March of 2020, which stalled the project.

SEKISUI KYDEX and BUTTERFLY®, opted to use the next several months to refine parts on the project and introduce new technologies. KYDEX® surfaceGrip™ (anti-slip, soft touch cap) and KYDEX ION Technology™ (premium antimicrobial formulation) are just two of the materials being explored as potential additions to BUTTERFLY®2.0.

SEKISUI KYDEX is excited to continue to provide an innovation playground that combines high-tech equipment and a team of experts with a passion for creative solutions. At the SEKISUI KYDEX Innovation Centers, traditional methods are challenged, inviting collaboration between unlikely partners with the courage to disrupt the norm. The only limitation is one’s imagination.

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When attending high-profile conferences, most expect to network and come away with a few insightful ideas. What is not expected is to walk away with a plan and partners to fulfill an airline experience manager’s wish list.

But the 2019 RedCabin Aviation Summit isn’t for those who want a typical conference experience. Founded by Monica Wick, CEO, RedCabin is an exclusive aviation summit held twice a year which includes the best in the industry. The summit provides unique round table platforms to establish and renew relationships in the aviation interiors market.

One platform featured a panel focused on how seat OEMs could help airlines innovate aircraft seating and interiors. The panel was asked questions relating to the next generation of passenger experiences and what would be on their wish list required to fulfill those experiences.

The audience listened as Matthew Coder, Onboard Experience Manager at Alaska Airlines, detailed his dream economy class seat. It would feature three tray table variations: one for drinks, one for snacks, and one for work. The wish list included a “super widget” capable of informing passengers of everything from the name of the captain flying the plane and their credentials to lavatory availability. Other widgets would include the aircraft type and history, where the plane is in the takeoff lineup, cabin pressure and temperature, and even where a passenger’s pet is in the cargo hold. Coder finished his wish list by saying it would be great to achieve it and innovate for the economy class, but that this was years in the future.

Ronn Cort, President & COO of SEKISUI KYDEX, saw an opportunity to bring panel members, Elina Kopola and Patrick McEneany of TrendWorks, together with Matt Malejko, appLab™ Consultant, Rick Wood of ROLLON Corp, and Bernadette Chupela, SEKISUI KYDEX’s Customer Experience Manager, to explore the possibilities of the appLab™. This was a prime opportunity to take dialogue from the RedCabin Aviation Summit to the next level by delivering a seat back prototype a few years earlier than Coder expected.

Not wanting to be held back before truly beginning, SEKISUI KYDEX wanted to ensure that the materials for this project were already found in the air. Recognizing that frequently great ideas never take flight in the aviation industry if they aren’t presented in a flyable form, the economy seat project was executed in a way that although it might not be on the next flight you take, it is fully capable of moving to the next stage of flight compliance. The team set out to show that innovation and new ideas are possible in an industry looking to elevate ideas into reality. TrendWorks’ Kopola and McEneany were inspired by Coder’s wish list and started brainstorming for a dream economy class seat.

THE A/B PROJECT

The team drew from the idea of A/B testing for successful innovation and combined it with one of Alaska’s most well-known features, the Aurora Borealis. Just as the energy at the RedCabin Innovation Summit excited attendees, the energy from the aptly named A/B project crossed continents and built bonds, unifying everyone who had a hand in the completion of the Aurora Borealis Seat Back.

Kopola and McEneany introduced different elements of Coder’s wish list, and created seven wonders of economy class seating. These conceptual designs introduced split tray tables, adjustable heights, textures, and opportunities for passengers to be fully connected with their devices while onboard. The team chose TrendWorks’ first seat back iteration, which incorporated most of Coder’s wish list. With the expertise of the appLab™, TrendWorks, and Malejko, the team was ready to turn a concept into reality. While the team isn’t comprised of seat OEMs, they leapt at the chance to push boundaries in the appLab™ while building on past and present innovations in economy seating.

Concept 01 introduced a split tray table designed for touch and flexibility, a textured modular insert, an appBar full of information for the passenger including coloured light indicators, a media easel for personal devices, and a multi-pocket pouch for in-flight essentials.

“I wanted to take all the very diverse passenger needs into consideration to create something that was comfortable, yet practical. The combination of the beautiful pearlescent finish (of KYDEX® Thermoplastics) with some tactile, more crafted elements to enhance the passenger experience was essential. The contrast of the 3D-knit fabric with the pearlescent seat shell was intentional to make the Aurora Borealis Seat Back feel more human,” explained Elina Kopola, Founder/Director of TrendWorks.

While TrendWorks’ Concept 01 had determined the basic design for the project, Colour, Materials and Finish (CMF) had to be decided early to ensure they were received in time for the building phase of the project. As with any project design phase, Kopola and McEneany drew inspiration from multiple elements. From textiles to material finish, the design possibilities were endless. They pulled from Amazon’s Alexa, recent fashion shows, and the automotive industry to build the Aurora Borealis Seat Back design aesthetic.

Designed with the passenger in mind, the 3D knit pocket from Kobleder includes multiple ways for passengers to arrange their personal items. The process of nesting and customizing the area for comfort, referred to as “micro nesting,” is supported by this unique pocket design. Passengers can get comfortable in their space with a spot for accessories to rest securely during travel.

To add threads of navy, white, and khaki to the tapestry woven from RedCabin, the team also created colours (Arctic Lustre, Sneaker White, Night Sky, Salmonberry, and Glacier Blue) to echo those in Alaska Airlines’ newest lounge in Seattle, WA, with assistance from designLab®.

SEKISUI KYDEX’s designLab® specializes in custom colour creation and quick turnaround. Kopola and McEneany provided inspiration for the designLab® to create a custom palette for review. As any designer will attest, seeing colour in person is necessary to truly choose the colour best for any project. Kopola received several colour creations at her London office, just a few short days after sending over her colour inspirations.

The colours of the thermoplastics were amplified as the team reviewed textiles of leather, mesh, and suede. Adding an element of touch to enhance the passenger experience was important to the team. Utilizing SEKISUI Alveo foam and Rohi fabrics on the back of the seat tray design, passengers could feel comfortable in close quarters while their tray tables were in the upright position. Textiles from Kobleder were also chosen for the 3-D knit literature pocket showcased behind the split tray table. Passenger comfort was not only at the forefront of the CMF design, but also in the engineering phase and throughout the more technical aspects of the seat back.

BLUEPRINTS TO BLUE SKY

The A/B Project jumped from blueprints to forms the team could actually touch and refine. A seat form made of industrial foam from MachineHistories provided the base for the next few months of innovation. SEKISUI KYDEX’s appLab™ was the playground, with two CNC routers, a full-size pressure former, and a bevy of precision equipment at the team’s fingertips.

The project shifted to technical elements beginning with the tray tables, where the team moved forward with a split tray table design. While one of the smaller parts of the Aurora Borealis seat back, it played to some of Coder’s most important, non-technology-based passenger experience must-haves. Each tray table could be used separately or simultaneously, making it easier to juggle the electronics and personal items many passengers bring on flights.

“The split tray table was a decision made really early in the process, and one that was completely crucial. It’s what gives the seatback more of a furniture feel. It also allows the passenger to feel more in control of their own environment,” explained Kopola.

This divided tray table on a non-reclining seat back required custom mechanisms. ROLLON Corp fabricated the hardware while machinery company, Berwick Machine, LLC, worked with the team to customize the hinge mechanism. The two pieces allow the split tray table to move with ease.

“The hardest part was getting it all together with the final fit and finish. The most fun but the challenging part is taking concepts and making them function. Going from a drawing to a reality while trying to foresee any issues that may come up has been part of my role for the past 30 years. It was interesting to do this as part of a larger team in the appLab™, but everyone wanted to help solve problems,” said Matt Malejko, appLab™ Consultant.

Shawn Gum, appLab™ Applications Engineer, detailed specifics about his role in the project: “I’ve learned so much with the CNC machines over the past couple of months with the A/B Project. From revising a 3D model through SolidWorks, finding the origin, and then creating and refining the tool path to cut molds, it’s been a journey of trial and error, but one that I’ve enjoyed. The more I struggled with the process, the more I learned and the easier every task became. It was an awesome exercise for our first project in the appLab™.”

While the team and appLab™ are mighty, they couldn’t do it alone. Led by SEKISUI KYDEX’s Customer Experience Manager, Bernadette Chupela, pulling in partners from the supply chain who could work at accelerated speeds was paramount. The seat back part was one of the most pivotal pieces for a successful project. While appLab™ was able to CNC mill out the smaller parts on site, such as the tray table, they needed help with the larger main seat back.

With renderings in hand, Orange Packaging milled out the seat back and modular insert parts from REN and aluminum material. Using this material, along with Orange Packaging’s expertise, ensured a quick turn around and clearly defined parts ready for thermoforming.

“This is the first time we’ve officially machined tools to use in the appLab™’s thermoformer for a project. Everybody took an active role with the thermoformer, pressure former, and vacuum forming, and changing tools out for this exercise in rapid prototyping. We designed, created, and put together the Aurora Borealis Seat Back in about six months, when in the aviation industry, sometimes that process can take up to two years. The A/B Project was different as we were working on a project as it shifted. We took designs and worked on the concept as we went, so the troubleshooting happened in real time, not after the fact,” said Matt Kline, appLab™’s Aviation Applications Engineer, when explaining the project.

Simple parts with flat surfaces weren’t going to make the impression the team wanted. Because texture is an important part in aviation interiors, adding dimension to the modular insert through bespoke texture was key. The team designed a texture which would also camouflage inevitable wear and tear the part may encounter. Custom Etch collaborated with Becky Gallup, SEKISUI KYDEX’s Infused Imaging™ Senior Graphic Artist, to laser etch the part in less than a week to deliver the texture to the team.

While the thermoforming mold parts were in development, Coder’s super widget was also coming to light. It became the basis for the Aurora Borealis Seat Back’s appBar, a one-of-a-kind creation by Aeolab. The appBar gives the Aurora Borealis Seat Back an opportunity to respond to the information that passengers need, and includes a light indicator fueled by an exclusive app. TrendWorks’ McEneany asked the group: “How can we create a digital feature that helps the crew and passengers communicate well, especially since the crew is the primary point of interface when a passenger boards the plane?”

The answer? The appBar, which features no-fuss icons for the plane’s trajectory, meals, restroom availability, luggage, and even a deep breathing reminder, depending on passenger preference. Each icon will subtly flash on the LED indicator with a red, blue, or amber light to signal “no,” “yes,” or “breathe,” respectively. The design included layering KYDEX® Lumina, SEKISUI Voltek foam and Tapis fabric to bring softness to hard technology.

“We wanted to address Matthew Coder’s request to create a new opportunity for interaction between the flight, crew, and passenger. The vision was for a more engaging overlap between the passenger’s own devices and the seat itself. Rather than providing a simple dock for passengers’ tablets or laptops, we wanted their own devices to communicate to the seat, and the seat to communicate back to them. The passenger can receive information from the plane as needed without it being overly bombastic. When you have 170 passengers on board asking questions through the appBar, you don’t want to light up the plane like Las Vegas. So we built in features that are subtle and make it more human,” said Patrick McEneany.

The Aurora Borealis Seat Back design includes a custom media easel made of KYDEX® 6503 in Sneaker White, which can be used as a device holder or folded out of the way to make efficient use of the passenger’s space. This media easel leaves the main tray tables space for other items.

COLLABORATIVE CRAFTSMANSHIP COMPLETE

The Aurora Borealis Seat Back had all the elements needed to fulfill Coder’s wish list. Over six months, they had collected fabrics, connectors, technology, thermoplastics, forming tools and molds, foam, and much more to build the prototype. The team encountered challenges as they worked to custom fit all the pieces of their puzzle together, but by utilizing the appLab™ and designLab® resources, they were able to construct their desired Aurora Borealis Seat Back prototype.

“It’s a full size, fully functional model we created in under six months. That speed is something that is impressive. It was the largest challenge coming out of the discussions at RedCabin: We needed to break down silos, share ideas, and move quickly in a more iterative process, but at the end of the session, many people were scratching their heads saying ‘yeah, but that will never happen.’ Having the opportunity to be invited to work together on Ronn’s vision, to show them, was the most important thing to us throughout this process,” said McEneany of TrendWorks about the rapid prototyping of the Aurora Borealis Seat Back.

SEKISUI KYDEX, Kopola, McEneany, Malejko, and Wood were pleased to share the final Aurora Borealis Seat Back prototype at the RedCabin Aviation Summit on December 4, 2019, in London. Presented on a custom pedestal outfitted by Bloomsburg Carpet, the Aurora Borealis Seat Back display will include an iPad for attendees to experience the unique features of the seat for themselves. This project has been an ambitious, but successful, journey.

“In response to the seatback prototype, Coder said he was ‘overwhelmed,’ and stated to the audience that ‘collaboration is the accelerant of innovation.’ When a delegate posed a question about whether having a pocket hidden behind the tray table meant people would be more likely to forget their valuables, the creators responded that there could be a sensor which flashed red if it detected there was still something inside the pocket at the end of the flight. This could be an indication that further collaboration is underway – perhaps a second version of the prototype will be showcased at the next RedCabin event.”

For SEKISUI KYDEX, the project is our guiding star for the customer experience when visiting our appLab™ and designLab® Innovation Centers. We will continue to define collaborative craftsmanship through rapid prototyping and shorter lead times from iteration to realization.

“The most rewarding aspect of the A/B Project was to see everyone using their specific talents to collaborate on the Aurora Borealis seat back. Having all of the partnerships and vendor relationships come together for one common goal with an ambitious vision and aggressive deadline is the epitome of what the appLab™ is for our customers— a common ground and resource to rapidly iterate,” said Chupela.

In a concluding word? “Elegant,” says Kopola, “from the lines of the seat back to the contour of the seat. Contrasting the tactile and elegance in the Aurora Borealis Seat Back is such an accomplishment for the team.”

While there is no official plan for a version 2 of the Aurora Borealis Seat Back prototype, we are excited for the possibilities and challenges of other future collaborations.

SEKISUI KYDEX thanks all of our valuable partners who made the A/B Project a success: Aeolab, Bloomsburg Carpet, Berwick Machine, LLC, Custom Etch, Inc., Kobleder, Lantal, Matt Malejko, Orange Packaging, MachineHistories, RedCabin, Rohi, ROLLON Corp, SEKISUI Alveo, SEKISUI Voltek, Tapis, and TrendWorks.

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Artificial intelligence and advanced technology are entering the medical market at unprecedented rates.

While some may be wary of how much we allow technology to have a hand in our medical care, many agree this is a step forward. The influx of medical AI technologies allows providers to keep up with fully occupied hospital rooms and patients who may be at a higher risk of injury.

With rotating shifts, daily room changes, and high standards of care, using technology as another set of eyes ensures patients’ safety. Avasure’s Telesitter® Solution is a virtual patient engagement platform able to continuously see, hear, and even talk to patients without recording video or sound.

Avasure’s Telesitter® Solution is rapidly changing the way healthcare can test, monitor, and care for those in need.

With a reported 50% reduction of composite fall rates, additional uses in mental health care, and easing loneliness for patients in isolation, the Telesitter® is remodeling the caregiver-patient experience.

“The Telesitter® is the ideal technology for a nurse or technician who continuously monitor patients and was created for high-risk patients who may be disoriented or could fall. The technicians can talk to the patient through the Telesitter® and send in medical staff to help during an emergency, and patients can also use it like a call button to call for help if needed,” said Brandon Reddick, Senior Product Developer at Avasure.

While the first version of the Telesitter brought innovation to patient care, Avasure wanted the second-generation Telesitter® to be more lightweight with increased mobility and softer aesthetics.

“An all-metal machine felt unapproachable to patients. We wanted to include a human quality in the product, which drove the material selection, shape of the body, and color scheme for the Telesitter®,” said Reddick.

Enter Formed Solutions’ Vice President of Sales, Cam Streidl. Streidl knew his company’s pressure-forming abilities could bring a less industrial, warmer look to the Telesitter. Because pressure forming has excellent fit and finish capabilities, similar to injection molding but with a more affordable tooling cost, Avasure was interested in working with Formed Solutions.

Formed Solutions’ expertise in pressure forming was ideal for the project, which had at least 12 parts that had to meet critical dimensional control and texture requirements. Ensuring that the material and parts worked together in a way that provided the Telesitter® with durability and a high level of precision detailing and aesthetics was something Formed Solutions was confident they could achieve. Their experience with utilizing multiple types of thermoplastics and forming processes also made them an expert in specifying the right material for the project.

The medical system had to resist damage from other machines and people, move easily, and withstand harsh cleaning supplies. Formed Solutions knew injection molded materials become brittle after repeated chemical exposure, so any material using PC/ ABS was out. PVC-based KYDEX® Thermoplastics were in, not only because of their high chemical resistance, but also because of their durability and design freedom with thermoforming.

“When you want to achieve beautiful formed in detail, and crisp, varying textures, pressure forming with KYDEX® Thermoplastics really makes a part pop. The contrasting texture capabilities and parts that snap-fit together through pressure forming are what set KYDEX® Thermoplastics and Avasure’s Telesitter® apart,” said Streidl.

Avasure’s Telesitter® is an AI enhancement that allows healthcare professionals to care for patients efficiently and effectively. With the benefits of KYDEX® Thermoplastics and the pressure-forming expertise of Formed Solutions, providers can be assured the Telesitter® is ready for the challenge.

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Experts in their Fields

Canfield Scientific and HS Design partnered to create the Vectra WB360, the world’s first 3D whole-body imaging system. Kenson Plastics, the thermoformer partner of choice, knew they needed a thermoplastic material that would accommodate a large, deep mold. It would have to stretch across complex geometries, remain strong even with a severe undercut, and meet stringent safety regulations.

KYDEX® T: The Perfect Fit for the Vectra WB360

“We told our client that KYDEX® T was the way to go,” says Robert Boyer, Director of Product Development at HS Design. “We looked at structural foam, RIM, and thermoforming. There were many requirements, such as keeping it lightweight, and aesthetics were also a big part of it.”

“KYDEX® T was ideal,” explained David O’Leary, Kenson Plastics’ founder and Vice President of Sales. “In fact, the project wouldn’t have worked without it. We pushed it to its limits in terms of stretching and formability.

Other materials would have torn. We were all thrilled with the outcome.”

Elevating Technology Through Design

“KYDEX® T was perfect because it can handle deep draw and the undercuts,” says HS Design’s Senior Industrial Designer, Stephen Simantiras. “We wanted the injection molding/ RIM look without the weight. Durability was also extremely important, if the final product is in a hospital or ER setting, someone wheeling equipment around could bump into it. If we’d used something like RIM or structural foam, the impact could chip or mar the paint.”

“One advantage of KYDEX® Thermoplastics is colour,” Boyer adds. “If you nick or scratch it, the material’s colour is embedded, whereas with RIM you have to paint, which is another step and expense. Beyond aesthetics, another advantage was KYDEX® T’s excellent V-O rating.”

The Vectra WB360 project required design and manufacturing to meet the highest standards. The design is flexible in case a camera location changes and is precise so the system could deliver the highest-quality imaging.

“The cameras have to be in a specific spot at a certain angle,” says Boyer. KYDEX® Thermoplastics pieces have to line up perfectly with the cameras, so some have unusual undercuts, and the bends and cutouts are intricate.” “In the end,” adds Simantiras, “only the camera pods are injection molded. Everything else is thermoformed with KYDEX® Thermoplastics.”

Forming Partnerships

“One of the great things about working with KYDEX® Thermoplastics,” Boyer says, “is that they’re willing to try unique or difficult applications. Other vendors just say no.”

”We have partnered with HS Design on many new programs in the past,” says Canfield’s CEO, Doug Canfield. “This program was especially challenging due to the size and volume of the system. Collaboration with KYDEX® Thermoplastics, HS Design, and Kenson Plastics allowed us to meet our objectives while satisfying the high-end look and feel that is associated with Canfield.”

“Our experience working with KYDEX® Thermoplastics makes our projects achievable and easier,” O’Leary says. “They address our needs quickly, provide fast turnarounds on colour samples, and respond to any issues right away. Partnering with them is a win-win for everyone.”

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THE TECHNOLOGY

Upon reading an article in Scientific Magazine regarding ultrasonic technologies, Riccairdi set out on a journey to develop an economical solution for use in the medical field.

“In 2019, the CDC made a statement that the world had reached the end of the antibiotic era. The superbugs and pathogens have won. People must adapt habits of remaining hygienically safe. Altapure offers a strategy to make hospitals, nursing homes, and other areas as safe as safe can be,” says Ricciardi.

Altapure was created as part of an initiative to deliver an advanced ultrasonic product capable of delivering a dense cloud of sub-micron fog droplets (0.69 micron avg.) for high-level disinfection of large spaces such as those found in hospitals, burn units, clean rooms, and long term facilities. Featuring a dry fog, the device is safe to use with highly sensitive electronics in the healthcare environment.

Altapure developed a string of products from Big Blue to Blue 2, and ultimately the AP-4™. The latest design boasts new high-level engines and thermoplastic skins. The AP-4™ version was the first to introduce thermoplastics as part of the design.

THE MATERIALS

Altapure partnered with General Plastics to convert fiberglass covers to thermoformed KYDEX® Thermoplastics. Fiberglass parts are labor intensive and are hazardous to the environment. Altapure required a technology that met their growth plans and was easy to maintain in a health care environment.

When Altapure brought this project to General Plastics, they needed a material that was chemical resistant, met UL certified unit 94 V0, and was aesthetically pleasing. General Plastics immediately recommended KYDEX® Thermoplastics.

KYDEX® Thermoplastics are inherently antimicrobial and are durable, chemical- and stain- resistant. They are easy to disinfect and are ideal for medical devices.

“We like the challenge of difficult and complex parts with difficult timelines. We want to meet customer needs and desires while working together to make a finished product we are all proud of,” said Bob Porsche, President of General Plastics.

The AP-4™ uses KYDEX® T in vacuum pressure parts in two custom colours. General Plastics produces seven parts per unit and has further designed the parts to remove undercuts from the third version.

We encountered some early challenges because some of the tools are male and some are female. We had some gloss issues, that we quickly remedied by adding texture to the side panels. Originally, the intention was to paint this part but once we started using KYDEX® Thermoplastics, painted parts weren’t needed.” said Porsche.

By transitioning to thermoforming, General Plastics was able to reduce operating expenses by removing a step in Altapure’s production process - parts no longer required painting. Another benefit is AP-4 looks better longer. “After five years of continued use and regular cleaning cycles of the unit, AP-4 looks as good as new,” said Ricciardi.

THE FUTURE

“A clean and disinfected healthcare environment has always been essential. With its importance at the forefront of people’s minds, we’re now seeing a need for disinfecting technology outside of the hospital and in our everyday lives. Altapure’s system can seamlessly expand its capability into our schools, nursing homes, restaurants, and other public environments.” said Mark Denning, Medical Market Business Manager, SEKISUI KYDEX.

This project is an example of how we partner with customers by meeting them where they are and forming partnerships that exceed their expectations.

“General Plastics provides complete service from the initial first sales contact thru the final shipping logistics. All of their great stuff - managing technical details - is packed in the middle to ensure the project success and complete customer satisfaction. Our industry expertise and well established relationships with suppliers like SEKISUI KYDEX allow us to create products our customers envision, which we’re all proud of,” said Bob Porsche.

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