Success Story: Delivering Smart Motion for Premium Bus Seating
Success Story: Delivering Smart Motion for Premium Bus Seating
The Smart Headrest Solution
A leading North American bus seating company, known for its high-quality seating in executive and first-class buses, needed more than just comfort—they needed control. In particular, they were seeking a friction hinge that could provide asymmetric torque for adjustable headrests, helping to enhance rider comfort and ergonomics. When their current supplier failed to meet delivery demands, they turned to Reell.
The Challenge: A Hinge That Couldn’t Keep Up
At the time, the seating manufacturer was using a competitive hinge that met functional expectations but failed to deliver at scale. Their supplier's inability to meet production capacity threatened both project timelines and customer satisfaction. Reell offered a high-performance hinge alternative, but only in a symmetrical torque configuration—missing the key asymmetric function the customer needed.
Recognizing the opportunity, Reell proposed a solution in the form of a new over-molded hinge design that would match the desired functionality, offer better performance, and solve ongoing supply chain challenges. The task? Develop a reliable, durable hinge with asymmetric torque, reduced weight, and proven delivery capability—all within a tight timeline.
The Solution: The Reell MH-10
Reell responded with a 50mm x 50mm asymmetric over-molded torque hinge, offering 3.5 Nm of torque in the high-torque direction. This was no off-the-shelf fix—while designed to become part of Reell’s standard product catalog, the MH-10 was heavily influenced by the specific demands of the bus seating application.
Key engineering wins included:
• A 60% reduction in weight compared to the metal predecessor
• Compatibility with the existing bolt hole pattern
• A faster and more cost-effective manufacturing process using plastic over-molding
Reell also addressed concerns about durability. Some initial failures in a drop-in metal hinge had created concerns of in-field failures. Using FEA analysis, Reell engineers fine-tuned the design for durability, confirming the strength of the over-molded hinge was on par with its metal counterparts. This iterative process reassured the customer and cleared the way for implementation.
The Results: Performance, Delivered
The MH-10 is now the preferred hinge in the headrest assembly of the customer’s premium seating lines. It offers smoother motion, reduced part weight, and secure positioning—delivering both engineering confidence and enhanced user experience.
Application Outcome Highlights:
• Reliable asymmetric torque for ergonomic headrest positioning
• Reduced assembly complexity due to over-molded design
• Timely, consistent delivery supporting high-volume production schedules
The Road Ahead
The success of the MH-10 has opened the door to additional projects between Reell and this premium seating manufacturer. As new opportunities emerge for controlled positioning in bus interiors, Reell is actively developing friction hinge solutions for accessories beyond the headrest.
When it comes to adding smart motion to seating comfort, Reell continues to prove that precision matters—especially when reliability rides on it.
From Concept to Completion—We’re Here to Help!
Let’s talk. Reell’s engineering team specializes in designing custom solutions that meet your exact torque, space, and performance requirements—no matter the application.