Seating Foam

Job title: Seating Foam Engineer

Department: Seating Systems / Product Engineering-Foam

Job Purpose

Responsible for the design, development, validation, and release of seat backrest, cushion, headrest and armrest foam systems (PU molded, cut foam, EPP) to meet comfort, durability, safety, and cost requirements, ensuring compliance with ergonomic and regulatory standards for automotive seats.

Key Responsibilities

• Expertise in design and manufacturing of foam pads of all rows of seat Cushion/back/AR/HR foam pads
• Create criteria sections confirming to comfort and packaging guidelines.
• Create 3D CAD surface models of foam profiles and integration with seat trim and structure. Coordination with Style team for STO convergence to meet comfort and feasibility requirement.
• Coordinate with JIT Integration and Trim team and structure to define optimum attachment scheme and comfort to meet craftsmanship requirements.
• Deep knowledge of foam tool design, manufacturing process (DFAM) and costing
• Responsible for supplier and CFT convergence with CAE for foam stiffness ,H-point and NVH simulations
• Responsible for quality improvements, weight reduction and cost reduction.
• Define and execute DVP&R for foam systems including comfort, fatigue, thermal aging, humidity, flammability tests.
• Work with suppliers for mold tool design, component feasibility, tooling, and manufacturing process validation.
• Ensure foam designs meet ergonomic, safety, flammability
• CAD Data finalization and release per program milestones.
• Co-ordinate TKO sign-off processes and ensure targets are met.

Key Skills and Competencies

• Knowledge of PU foam manufacturing processes (molded foam, cut foam, dual-density) and foam materials.
• Proficiency in CAD software (CATIA, NX) and PLM systems (Teamcenter, Enovia). Understanding of foam chemistry, comfort metrics, durability requirements and different testing methodologies
• Familiarity with DFMEA, APQP, PPAP processes. Knowledge of regulatory standards (ECE, FMVSS, AIS) for flammability and safety.