Ultra Slim Seat
Take a seat - the challenge of lightweighting commercial aircraft
Travel restrictions permitting, it is likely that the low-cost carrier market will see a strong uplift in the second half of 2021 and beyond, as there is significant demand for overseas holidays. In the wake of the pandemic, airline passengers will be looking to return to the skies safely and with value for money, as well expectations for an attractive product offer.
Recent events have made us all question what’s important and opinion has sharply focused on sustainability. With a clearly defined road map, it’s my firm belief that innovation will drive change in the aviation industry.
The most obvious place to start making meaningful efficiencies is within the cabin. Airlines are under intense pressure to shore up their balance sheets and there’s no doubt in my mind that simpler, easy clean, high density cabins with better space efficiency will be top of the agenda. We need high density cabins to get the most value from the energy we use to fly. To deliver this, however, comes down to saving every possible gram in weight and millimetre of space which, when scaled up across a fleet of aircraft, starts to pay dividends.
In March 2020, I was due to launch a pioneering new aircraft seat at AIX Hamburg, which had to be cancelled due to Covid-19. Called ‘Ultra-Slim’, it was billed as the “the world’s thinnest aircraft seat”, which would offer a step change in creating more passenger space for single-aisle low-cost carriers.
“Saving over 500kg on an A320 with the seats alone is a significant step towards a more sustainable future.”
Weighing in at under 7kg, this disruptive innovation was designed to offer flexibility and cost savings through a completely sustainable and pioneering primary structure. Crucially, Ultra-Slim would enable operators to reduce overall cabin weight by over 500kg per aircraft, when compared with existing lightweight economy shipsets.
A process of ‘snap cure’ manufacturing, involving a bio-resin laminate developed by composite specialist Cecence, makes Ultra-Slim a much more environmentally friendly product and comparative in strength to existing phenolic and epoxy resins used in seat assembly. The cost benefits are potentially enormous, not only in terms of cheaper construction and reduced cost of ownership but also through massive reductions in fuel burn.
To prove the concept and verify its design, Ultra-Slim has been developed into a
working prototype. Its curved surfaces provide an entirely new feeling of space and a positive impression of comfort, which can be enhanced by different dress cover designs and materials, including the use of natural fibres. Furthermore, its improved operational serviceability with a particular focus on cleanliness is a critical factor for airlines in managing crew and passenger health as we emerge from the pandemic.
“Working with passengers and focusing on what we need rather than what we are used to could yield another 1000kg weight saving.”
Beyond seating, we can go further within the cabin environment and this is where collaboration with passengers on this journey to sustainability requires their engagement. We need to be honest about what’s really important in a sub 4-hour flight and this involves questioning the need for inflight meals and beverages. This could see the removal of galley carts, the rear galley and associated paraphernalia such as meal trays, accoutrements and even onboard merchandise that collectively, could reduce weight by over 1000kg.
By providing passengers with information regarding the sustainability credentials of carriers, they will be educated to make an informed decision about their own environmental footprint, which could mean measuring CO2 per passenger not per aircraft. Initiatives to provide passengers with a financial benefit for reducing baggage weight are also likely to feature in future marketing.
Society has become used to playing our part and separating our rubbish at home for recycling as part of our daily routine. With awareness and collective ambition, we can change behaviour and drive a more sustainable future for aviation and it starts by taking a seat and reimagining flying.
This is the time to step up and respond. It is time for action.