Rethinking, designing, and printing a sports car seat with Additive Manufacturing
Traditional automotive seat production is characterized by complex processes, often based on non-recyclable materials, glues, and chemical treatments that make disassembly and reuse difficult. Faced with these critical issues—high CO₂ emissions, water and energy consumption, and poor recyclability—Italdesign proposes an alternative vision that aims to simplify and decarbonize production, while maintaining high standards of comfort, safety, and design. The project therefore stands as a concrete response to the challenges of sustainability, technological innovation, and environmental responsibility that define the future of mobility today.
ReSedo represents a systemic solution based on an “infinity loop” circular model that combines modular design, recycled materials, and innovative processes. The seat is designed to be disassembled and regenerated at the end of its life, transforming back into raw material. Key technologies employed include metal additive manufacturing using 100% recycled powders, 3D-printed TPU padding that replaces foams and glues, and ZIRO fabric upholstery derived from recycled yarns (20% Nike Grind waste, 80% rPET). The “design for disassembly” approach eliminates glues and seams, facilitating material recovery. The entire system integrates lean processes and sustainable materials, with a recycled content of 65% and a weight of less than 25 kg, ensuring performance and comfort in line with high-end automotive industry standards.
CIM supported Italdesign during several manufacturing phases of the aluminum alloy seat structure. Specifically, it first supported and guided the design during the final optimization phase, providing its expertise in the Laser Powder Bed Fusion (L-PBF) process. CIM then internally managed the production of the various components into which the structure was necessarily divided, given the constraints of the EOS M400-4 build chamber size. Particular attention was paid to the setup of the additive process to ensure an optimal surface finish, given the project’s strong aesthetic focus. Following the printing, dimensional checks were carried out to optimize the production cycle, resulting in significant positive impacts on the final lead time.
The ReSedo project goes beyond simple regulatory compliance, positioning itself as a new benchmark for sustainability in the automotive sector. Its impacts include a significant reduction in environmental footprint, the integration of circularity principles into production chains, and a new paradigm of cross-sector collaboration, as demonstrated by the partnership with Nike Grind for the reuse of industrial waste. Italdesign’s approach combines design and ecological responsibility, proving that innovation, performance, and sustainability can coexist. Looking ahead, ReSedo becomes a replicable model for the automotive interior design of the future, capable of guiding manufacturers toward more regenerative, efficient, and conscious production.
Browse the white paper: https://www.italdesign.it/en/whitepaper/resedo/
Rethinking, designing, and printing a sports car seat with Additive Manufacturing
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