JAMES WU
DESIGN ENGINEER
05 / Research / Circular product system

Materials, assembly and a seat’s next life.

A group study of aircraft seating as a circular product-service system. My work focused on material choices, manufacturing routes and assembly of the primary structure, secondary systems and accessories.

PROJECTSustainable Aircraft Seat
MY ROLEMaterials, manufacturing and assembly within a group design
CONTEXTGroup project
Team project
Rendered modular aircraft seat concept on a dark backgroundInspect full-size image ↗
FIG. 01Modular aircraft-seat concept developed from teardown and circularity research.
01 / OVERVIEW

The project in a minute.

THE OUTCOME

Contributed the materials, manufacturing and assembly proposal to a group seat concept, alongside shared lifecycle and circularity studies.

What supports this? ↓
The challenge
Improve the material use, serviceability and end-of-life route of an aircraft seat, while separating long-life structure from parts that wear out sooner.
My contribution
Materials, manufacturing and assembly within a group design. The final report explicitly credits my work on materials, manufacturing and structural assembly; whole-product CAD and lifecycle calculations have separate team credits.
Read this in context
Group concept study. Whole-product CAD and lifecycle calculations are team outputs. Mass estimates differ across report submissions, so no single final reduction percentage is presented.
02 / THINKING

The choices behind the result.

Open a chapter to follow the work and the choices made along the way.

01 / ENGINEERING

Choose materials together with their production routes

My contribution covers the primary structure, secondary systems and accessories: material selection, manufacturing processes and structural assembly.

Inspect the supporting evidence ↓
02 / DESIGN

Design replacement around different component lifetimes

The group concept separates the long-life frame from replaceable mesh and accessories, within a proposed leasing, maintenance and recovery system.

Inspect the supporting evidence ↓
METHODS USEDTeardownLCAMaterials
03 / EVIDENCE

Results, and what they mean.

Group concept study. Whole-product CAD and lifecycle calculations are team outputs. Mass estimates differ across report submissions, so no single final reduction percentage is presented.

Materials

My documented contribution

Material, manufacturing and assembly work, explicitly credited in the final contribution statement.

Modular

Group system concept

Replace worn parts without replacing the entire seat; connect maintenance to material recovery.

Concept

Evaluation status

Lifecycle and mass estimates belong to specific design iterations, not a certified production seat.

Source notes & scope 2
  1. Sustainable Aircraft Seat Designpp. 20–24

    Final system proposal and individual contribution statement on p. 24.

  2. Sustainable Aircraft Seat Designpp. 12–18

    Earlier submission; its weight estimates are not interchangeable with the final system.

Aircraft seat teardown and component analysis board↗
FIG. 02The teardown exposed service, joining and material-separation constraints.
Aircraft seat material and lifecycle analysis↗
FIG. 03Material decisions were assessed with life-cycle and circularity reasoning.
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