Aerofoam Industries has noticed that car manufacturers have been focusing on seat aesthetics and comfort, and has thus decided to derive its new dress cover process from automotive seat design. However, greater refinement and testing is necessary to translate the processes and materials into aerospace, so Aerofoam has spent over three years researching automotive dress cover manufacturing before bringing a system to market that maximizes cushion comfort as well as dress cover aesthetics.
The research process saw members of the Aerofoam team work with an adhesive supplier to develop specialty glues which work with materials ranging from leather and synthetics, to fabric and backing materials. The backing fabrics are custom made, which allows the dress covers >to move around complex curves and stay wrinkle-freez.
Another highlight of this process is the foams used. Aerofoam recently unveiled graphite-filled comfort foams formulated for tear strength and durability, which allow for greater elongation - a critical factor in dress cover construction.
The company's design and pattern department can work from renderings, reverse engineer an existing style or design a cover and cushion from scratch, including options for stitching, embossing, and complex shapes. Aerofoam uses 3D-design software to ensure dress covers fit smoothly around complex curvatures such as headrests and seatbacks.