EV360: Monowheel – Seat – Jolán von Plutzner

The EV360 project has many components, not least of which is the seat. Due to the aggressive position that our team driver will adopt, it is imperative that the seat feels as though it provides sufficient stabilization for the driver while maintaining an aerodynamic form factor; the solution space lies somewhere in between a road-bike seat and a booster seat.

I created a seat design in Fusion360 based off of BMW Motorcycle Seat concept images. I believe my design fulfilled the needs of the seat; it was wide enough to accommodate the average distance between ischial tuberosity (sit bones), with enough padding on either side to protect the inner legs from the motor mount panels. In addition, it matched the overall aesthetic and would allow the drive to feel comfortable while balancing within the frame.

The seat prototypes began with a laser cut insulated foam block. Through multiple prototyping iterations, I casted the seat base in silicone, then molded a new model with clay, and finally casted with expanding urethane foam to create the most recent edition. My ownership of the process began when the first silicone mold was determined be ttoo narrow, and a wider version needed to be casted and poured.

The next feat was to upholster the seat with white vinyl leather, with accompanying black accent stitching. This task came to me as I have plenty of previous sewing experience.

I created this video containing footage of the design and prototype process:

This seat has its flaws, and may not end up on the final vehicle which takes the world record, but it was great fun to create as well as an awesome learning experience. From CAD design in Fusion360 to my first foray into leather upholstery, it was an overall positive experience and great self-teaching tool.

UPDATE

After partnering with Stratasys 3D Printing, the seat design possibilities have increased significantly. With the ability to 3D print in varying polymers on a large print bed, I can now design a seat and back combination to be manufactured in two pieces including leg guards to protect the driver’s thighs from abrasion against the aluminum battery shields.