Ford Eyes “3D-Knitted” Seat Covers

Ford Motor Co.’s European unit is exploring 3D-knitting processes to produce customized seat covers.

The technology, which is being introduced in the apparel and furniture industries, inputs the dimensions, data points and material into a special 3D printer. The system can produce a seamless one-piece cover with the surface texture of woven material in about an hour. By comparison, Ford says it may take a full day to stitch a similar cover by conventional methods.

The new process can be applied to various fabrics and other materials, including blends and even conductive metals. The latter would allow heating and cooling elements, wireless smartphone charging and electronic controls to be integrated into upholstery, according to the carmaker.

3D knitting also promises to reduce in-process waste, because the machine would know the exact amount of material to use. Other purported benefits include a cleaner look and greater design flexibility.

Ford envisions customers creating personalized seat covers that could be interchanged whenever they want. In addition to colors and different styles, such as breathable materials for hot weather, the covers could incorporate logos, graphics, side pockets or pet-centric features.

The process also could be used for other upholstered parts in the interior, the carmaker notes. No timetable was given for potential production applications.

Watch a video about the technology HERE.