!NEW! Seat Engineering at Opel: High-Tech Perfection with a Long Tradition

• Robot tested: Outstanding ergonomic AGR seats for Astra, Insignia and Meriva and co.
• Second row comfort: Heated rear seats make new Astra debut
• Learning curve: From box seat to 18-way adjustable seat with massage function in 117 years

Bernd, Werner, Oliver and Marius are full of enthusiasm for their task – repeatedly they rub over the side bolsters of the seat underneath them before simulating getting in and out while scrubbing across the leather. Somewhat stubborn and relentless but at the same time completely dedicated. Bernd, Werner, Oliver and Marius are inspection robots in the test lab of the Opel International Technical Development Center in Rüsselsheim. To be more precise, they consist of a friction pad covered with a jeans-like material and a foam layer that simulate the human posterior and thighs. “They are more than just robots for us – they are fully qualified members of the team. They perform an important job and therefore they all have names,” explains seat specialist Andrew Leuchtmann, Senior Manager Interiors at General Motors Europe.

The robot team simulates gets into and out of cars 50,000 times a week – equivalent to an entire lifecycle of a car. Both the premium and ergonomic seats targeting the seal of approval from the back specialists of Aktion Gesunder Rücken e.V. (AGR) as well the integrated comfort seats that come as standard are subjected to this ordeal. After the tests, the engineers can recognize whether the seats will be able to withstand future strains just by looking at the fabric structure. “The color has normally faded and the surface is scratched but the most important thing is that the foam underneath is ok and that the surface structure remains stable,” says seating expert Leuchtmann. If this is not the case, the premium and ergonomic seats Opel offers for the driver and front passenger need to be upgraded – after all, there have to last an entire car life, no matter whether it is in the Mokka, Cascada, GTC, Meriva, Zafira Tourer, Astra or Insignia.

“This is where we obviously benefit from our great experience,” says Leuchtmann. After all, the Rüsselsheim-based carmaker can look back on 117 years of seating heritage. The success story of ergonomically valuable sitting began in 2003 with the first AGR seal of approval for the Opel Signum, making Opel the first manufacturer to offer back-friendly seats in the middle class.

The offensive for healthy sitting at affordable prices was rolled out across the model range. Especially long distance and company car drivers are grateful for the system. The numerous settings available allow the AGR certified premium seats in the Opel Insignia to be perfectly adjusted for each driver, ensuring that they are relaxed and symptom-free even after many hours at the wheel. Since 2003, Opel has made democratizing good seats one of its missions and is the leading volume manufacturer in regards to ergonomic seats with the AGR seal of approval.

The new lightness of sitting in the Opel Astra Sports Tourer

Lightweight: AGR seats in the new Opel Astra have shed 10 kilograms in weight thanks to ultra-high-strength steels.

The structure is the most important component of the seat. It ensures the safety of the occupants and keeps them in the right position in case of an impact. However, at the same time is also normally responsible for the considerable weight - not so in the new Opel Astra Sports Tourer. The seats have shed 10 kilograms in weight thanks to ultra-high-strength steels. The engineers know exactly how much weight they can take out safely before even starting on the first prototype thanks to a computer simulation. Darker colors show stress peaks in the material that could lead to a breakage. “We really pushed our limits on the Opel Astra Sports Tourer and experimented a lot,” says Leuchtmann. Amongst others, numerous welding tests were necessary. “You can no longer weld if the material is too thin,” says the engineer.

Comfort guaranteed: The numerous setting possibilities ensure that everybody can find the ideal position. 

Once the first prototypes have been built and the fabrics or leather for the covers selected, Werner and colleagues can start their work. But before that, the team calculates to the load level the robots need to apply to the test subject. Furthermore, a team of experts consisting of men and women of different size and build are asked to take a seat with a pressure mat measuring the peak loads, for example where the sit bones make contact. “We test it with prototypes in the real car,” explains Leuchtmann. “Opel Meriva seat for example is higher and you enter differently than you do the new Opel Astra Sports Tourer where the seats are lower.” Testers also sit differently on a premium or ergonomic seat. Because of the especially good lateral guidance, the side bolsters are higher and therefore under more stress. The data obtained results in an average calculation for stress and Werner and co can be programmed accordingly.

Mobile wellness: Massage and ventilation function along with electropneumatically adjustable side bolsters and lumbar support make the AGR seats in the new Opel Astra true all-rounders. 

Nine human seating experts are also at work in parallel. They, for example, drive around in a new Opel Astra Sports Tourer – for hours on end and for countless kilometers. They test the four-way electropneumatically adjustable lumbar support, the extendable thigh support or the massage function, complete a comprehensive survey and give a subjective overall grade. Serial production can only start when the last weakness has been eliminated.

Opel Meriva first vehicle to receive AGR certificate for integral ergonomic system

The development of a new seat takes around five years – of those, the team invests two years in the implementation of new concepts. This was also the case for Opel’s flexibility champion, the Meriva. It is the first and to date only vehicle with the AGR seal of approval for its integrated ergonomic system. This includes the ergonomic seats along with the 84-degree opening FlexDoors, the versatile FlexSpace seat concept for the rear seats and the optional FlexFix bicycle carrier. Or take the Astra Sports Tourer for example. Thanks to advance development, which also considers customer feedback along with comments posted in forums and blogs, the optional FlexFold rear seatback that can be split in a 40:20:40 ratio at the touch of a button could be realized. Furthermore, heated outer rear seats are available as an option for the first time. The added level of comfort will ensure that the next major trip with family or friends is more relaxing.

To ensure that Opel maintains its frontrunner position in seating development, the engineers are already working on the next generation of the premium and ergonomic seats behind closed doors. “Maintaining our ‘knowledge head start’ over our competitors and consistently extending our production know-how is vital,” insists Leuchtmann. “That is why we develop as much as possible internally and even have some components delivered by our own plant in Kaiserslautern.” The front seat structures are made entirely at the Kaiserslautern plant. The near vicinity to Rüsselsheim also has logistical advantages. The goal is clearly defined: Seats of the future will be even more ergonomic, even lighter, even more stylish and even safer. “We still have a lot of new ideas on how the contouring can adapt even more individually,” reveals the expert. “And there is still more to come on the massage front.” The fact that further Opel models with premium and ergonomic seats will follow seems to be a matter of course especially as the company looks to democratize good sitting further. 

Historical Overview of Opel seat Engineering

1899 – The box seat: The whole Opel Patent Motor Car System Lutzmann including the seats is reminiscent of a carriage. The seats cannot be adjusted.

1929 – Lower position: 30 years later, the Opel 4/20 “Moonlight Roadster” still comes with a firmly fixed bench. However, the position is considerably lower and the passengers can stretch their legs.

1950 – More comfortable: The seats of the Opel Olympia are fixed to a metal frame and the longitudinal position can be adjusted. The backrests of the front seats can be folded forwards to facilitate rear seat passenger ingress/egress.

1956 – Continuous longitudinal adjustment: The continuously adjustable front bench and the adjustable backrests of the Opel Kapitän are a further milestone. The backrests can be set to the optimum position by pulling a lever and simultaneously applying pressure.

1968 – Sporty: The legendary Opel GT gets sporty contoured seats with integrated headrests. Extended cushions and a significantly improved shoulder section show which way development is heading.

1970s – Headrests: Opel optionally fits certain model ranges with headrests – such as the Monza, the Kapitän/Admiral/Diplomat models or the Rekord C and D. The Opel Diplomat B comes with height-adjustable comfort headrests, which can even be tilted forwards.

1978 – First height adjustable seat: Opel Monza drivers can adjust the height of the seat with ease thanks to a telescopic rod.

1994 – Safety with a capital ‘S‘: The seats in the Opel Omega B are comfortable and as an option electrically adjustable. The reinforced rear backrests and the side airbags make an important contribution to passive safety, crash tests with a load are conducted for the first time. In the rear, all three seats come with three-point seat belts and headrests.

2003 – The first AGR seal: The Aktion Gesunder Rücken e.V. (Campaign for healthy back) gives the 18-way electrically adjustable multi-contour driver seat in Opel Vectra/Opel Signum its sought-after seal of approval. Opel is the first carmaker to offer back-friendly seats in the midsize class.

2008 – Comfort seats: The standard comfort seats in the Opel Insignia offer numerous setting possibilities – the height can be adjusted by 65 mm (electric) whereas adjustments of 270 mm are possible in longitudinal direction – outstanding figures. The premium driver seat is AGR certified.

2012 – Ergonomic total concept: FlexDoors with an opening angle of 84 degrees, AGR-certified ergonomic seats and the FlexFix bicycle carrier convince the AGR experts and they award the Meriva with their seal of approval. The first and still only serial production car to receive the certificate for its overall concept.

2015 – Compact class wellness: For the first time the AGR-certified premium ergonomic seats of the new generation Astra are not just 18-way adjustable including side bolster adjustment but are also optionally available with further comfort features such as massage and memory function along with ventilation

!NEW! AGR Ergonomic Wellness seats for All-New Opel Astra

• Art of German engineering: All-new comfort seats from Opel
• Unique in compact class: With massage and memory function, plus much more
• Tradition at Opel: AGR (Campaign for Healthier Backs) seal of approval
• Attractive offer: Ergonomic AGR driver’s seat already available from 390 euros

Unique in the compact class: Beyond being 18-way adjustable including side bolster adjustment, the Astra seats are now optionally available with massage and memory function along with ventilation.

The new Opel Astra celebrates its world premiere at the International Motor Show (IAA) in Frankfurt this fall (September 17 – 27, 2015), but it is already clear today: never before has there been so much luxury in the compact class. The Astra is lighter, more efficient and offers state-of-the-art features; thanks to its advanced seating technology, it makes every drive a relaxing journey. AGR (Campaign for Healthier Backs) certified premium Opel ergonomic seats provide excellent long-distance travel seating comfort. They continue the Opel tradition of award-winning, back-friendly seats. Beyond being 18-way adjustable including side bolster adjustment, they are now optionally available with further comfort features such as massage and memory function along with ventilation – a unique combination in the compact class. Rear seat passengers can also look forward to more luxury – in addition to more legroom, heated outer rear seats are optional. Astra customers can treat themselves to these luxury seats that are completely developed in-house at Opel for very attractive prices – the driver’s seat with the AGR seal of approval is already available from 390 euros.

Ergonomic AGR driver’s seat is already available from 390 euros.

“Seating is among the most important elements in a vehicle as it delivers safety, comfort, and design. It is one of the reasons we place such a high priority- with the support of our partners- on the development of our seating systems," says Charlie Klein, Vice President Vehicle Engineering at Opel. "The new Opel Astra seats continue to deliver on the promise of excellence and are a reflection of the skill and commitment of our engineers and designers. The Astra seats provide advanced features in the compact segment that are normally found only in the premium class."

Lightweight: Seat alone ten kilos lighter

Development of the seating environment in the new Astra already began nearly five years ago for the over 100 employees in the team of experts. “Especially integration of the relatively bulky seats must be considered from the very beginning. This means the seats have to fit into the car accurately to the last millimeter – in every direction,” says Andrew Leuchtmann, Senior Manager GME Interiors. A very challenging task, as the seat components are one of the car’s largest parts. Seat production alone accounts for around ten percent of the total production costs of a new car model.

At the same time, the seats have a large impact on total weight. That is why for their new development, the engineers first had to minutely examine all single elements of the Astra comfort seats that come as standard. “Compared to the predecessor, not one single part is identical,” says the expert. In order to offer rear seat passengers 35 millimeters more legroom, the seat back of the new comfort front seat was made much more compact. State-of-the-art calculation methods enable this, as do lighter polyurethane foams and ultra-high-strength steels that are built in under the seat upholstery. “So the new seats are around ten kilos lighter than those in the previous model,” explains Leuchtmann. This is not only true for the driver and co-driver seats – the new Astra’s rear seats are also lighter and more compact, their contouring was optimized and thigh support was enhanced with a steeper seat tilt.

AGR seal of approval for ergonomic seats

“In-vehicle ergonomics is more than just the seat contouring, it already begins with the positioning of the seat in the car,” says Leuchtmann. The Opel experts also further optimized the Astra comfort seat in this regard, positioning it lower. “This especially accommodates taller drivers with a sporty driving style,” he explains. Thanks to a 65-millimeter height adjustment span – the largest in the segment – shorter drivers are also guaranteed an optimum seating position. With the optional premium ergonomic seat’s memory function, this can even be saved at the press of a button. This is ideal for fleet vehicles with the same group of drivers or couples who share the new Opel Astra. The base version of the optional ergonomic seats comes with four-way electropneumatically adjustable lumbar support (forwards, backwards, up and down), variable seat cushion tilt, cushion length adjustment and a seat form with contours that adapt to the natural curvature of the spine. The premium ergonomic seats also feature electropneumatically adjustable side bolsters that support the body by making the seatback narrower or wider. All these exemplary ergonomic elements made it clear to the AGR (Campaign for Healthier Backs), an independent association of doctors and experts dedicated to preventing back problems, that the new Astra also deserves the AGR seal of approval.

Wellness massage, climate control and heating included

Seats should not only keep drivers securely in place, they should also keep them warm or cool depending on the prevailing conditions. The new Astra comfort seat features passive climate control, meaning breathable surface fabrics and perforated polyurethane foams that considerably improve transporting away moisture and thereby the micro climate in the seat. The new Astra’s premium ergonomic seats can do both – keep warm and cool. Small fans suck air, and thus the moisture that develops when someone is in the seat, away from the body. In the winter, integrated seat heating keeps the driver and co-driver as well as both outer rear seat passengers comfortably warm. Those who want to turn their car into a wellness mobile on longer journeys can enjoy a massage at the push of a button – and arrive at their destination even hours later relaxed and free of aches or pains.

Opel Signum (2003)

Opel Signum (2003) - First Opel with Ergonomic AGR seat.

Opel is the leading volume manufacturer of ergonomic seats with the AGR seal of approval. The first ergonomic Opel seat was introduced with the Signum in 2003. Today, in addition to the new Astra, the certified and popular seats can be ordered for many Opel models including the Insignia, Meriva, Zafira Tourer, Mokka and Cascada. “We want to really speed up the democratization of good seats – more Opel models with AGR seats will follow,” promises Andrew Leuchtmann.

!NEW! Premium AGR seat: Opel’s Ergonomic Answer to Driver Fatigue

• Very ergonomic seats for Opel flagship Insignia, flexibility champion Meriva and Co.
• AGR (Campaign for Healthier Backs) gives stamp of approval
• State-of-the-art seats account for 10 percent of production costs

Top comfort for the Opel Insignia: Thanks to a range of adjustment functions, drivers can optimally adjust their ergonomic premium seat so that even after hours of driving, they arrive at their destination rested and free of pain.

The new Opel Insignia and new Opel Meriva are in demand: on the market since fall 2013 and early 2014, both models are hugely popular. Since its introduction, over 115,000 orders have been received for the new edition of the Opel flagship. And the upgraded version of the Meriva flexibility champion has been ordered more than 50,000 times in just a few months. The vehicles are not only distinguished by their ultra-modern engine technologies and advanced infotainment systems, they also ensure that the driver and co-driver have an extremely comfortable journey. AGR (Campaign for Healthier Backs) certified premium Opel ergonomic seats provide excellent long-distance travel seating and back comfort. Thanks to a range of adjustment functions, drivers can optimally adjust their seat so that even after hours of driving, they arrive at their destination rested and free of pain. But before such an advanced and back-friendly seating design makes it to series production, many developments steps are necessary. There is a good reason seat engineering accounts for around ten percent of the production costs of a car.

Ergonomics and flexibility champion: Opel Meriva is the first car that received the AGR seal of approval for its certified ergonomic system.

Collaboration between Opel and AGR for optimum seating comfort

“Seats are veritable engineering masterpieces that include lightweight material, specific foam structures and numerous motors to carry out a multitude of tasks, such as heating and adjustments,” says Andrew Leuchtmann, Senior Manager GM Interiors, who is responsible for seat engineering. “Today, our seats are made to suit every size of person – tall, short, big, small – and this is critical to reduce fatigue on short or long trips.”

The very first Opel ergonomic seat was introduced with the Signum in 2003. Today, the ultra-modern and very popular Opel seats, which are the result of more than a dozen years of work and tight collaboration with the AGR (Campaign for Healthier Backs), an independent association that works on preventing back problems, can be ordered for many Opel models from Insignia, Meriva, Zafira Tourer to Astra, Mokka and Cascada.. The seats are developed in-house and safety is a major requirement for Opel. Safety aspects include airbags, occupant sensors and seat-belt tensioners. All these functions ensure that drivers and passengers in Opel cars always reach their destination safely and comfortably.

Opel is the first volume manufacturer to receive the AGR stamp of approval for its seats. To achieve this, four basic ingredients are required: four-way lumbar support (forward, backwards, up and down), cushion tilt, cushion length adjustment, and contour and body support.

“We worked together and combined their know-how with ours,” says Leuchtmann. “In the early days, different manufacturers claimed their seats were the best, but fleet managers often received complaints from drivers suffering from back and other pain.” Put simply, two-thirds of a person’s body should be in contact with the seat to avoid pressure points, which eventually translate into aches and discomfort. “Our seats,” Leuchtmann adds, “can be enlarged or made smaller to provide an ideal fit for any driver.”

Integrated Climate Control

“Seat construction is quite complex – we need to keep in mind foam construction, electrical comfort features, safety devices, headrests and more, and all this is apart from the structure, suspension nets and other support for users,” says Leuchtmann.

Integrated climate control: Ventilated seats are available for Opel Insignia and Opel Cascada.

One of the more complex jobs seats have to do – apart from providing support – is to keep users warm or cool in different conditions. “The seat climate is very important as you need to ensure, that moisture generated by the occupant is removed. Integrated channels make fabrics breathable and remove this moisture. With ventilated seats, small fans are inserted that effectively help keep drivers cool and dry,” says Leuchtmann. This system is available on the Insignia and Cascada. On the other hand, heating is also critical. “We heat nearly the entire seat surface,” Leuchtmann notes, which makes a considerable difference compared to systems that only heat parts of the seat.