About the Client

A European OEM specializing in off-highway vehicles, seeking to improve operator comfort through the development of an advanced, modular armrest system that could adapt to varying user preferences and rugged field environments.

The Challenge

The client required a fully modular 6 Degrees of Freedom (6DOF) armrest capable of enhancing ergonomics, durability, and adjustability in demanding off-highway applications. The design had to be robust, user-centric, and production-ready, while supporting easy integration into multiple cabin platforms.

Key challenges included:

• Achieving multi-axis adjustability while ensuring mechanical stability
• Designing for ease of assembly and modular reconfiguration
• Withstanding the rigors of harsh operating environments
• Balancing comfort with manufacturability and cost-efficiency

The Solution

We delivered an end-to-end design solution, combining ergonomic research, digital simulation, and rapid prototyping.

Key solution stages included:

1. Requirements Gathering
   • Collaborated with OEM teams and end users to define comfort, range-of-motion, and durability goals
   • Captured specific use-case scenarios unique to off-highway operations
2. Conceptual Design & Engineering Analysis
   • Developed multiple armrest concepts with 6DOF capability
   • Conducted performance simulations to validate strength, range, and fatigue resistance
   • Prioritized user comfort and long-duration support
3. Component Development & Prototyping
   • Designed modular components optimized for manufacturing
   • Used rapid prototyping techniques to build functional prototypes
   • Conducted ergonomic assessments and on-vehicle fitment checks

The Impact

The client successfully validated the design and moved forward with production tooling:

• Improved operator comfort via adjustable ergonomic support
• High functionality in rugged environments through robust design engineering
• Faster decision-making due to rapid concept validation
• Modular design approach enabling future platform reuse and customization
• Client approved the armrest for full-scale production after successful prototype evaluation