Engineering Excellence in the Sky: Designing the Cathay Pacific A350 Business Class Seat

At I.M. Bohannon Mechanical Design, we thrive on solving complex engineering problems that blend comfort, performance, and innovation. One of the projects that best represents our capabilities was leading the mechanical design of the Cathay Pacific A350-900 and A350-1000 business class seat furniture. This program demanded precision, creativity, and the ability to balance form and function in one of the most competitive markets in the world: premium airline seating.

 

The Challenge: Comfort Meets Complexity

Business class seats are more than just chairs, they are highly engineered environments. Passengers expect comfort and luxury, while airlines demand reliability, efficient use of space, and long service life. The A350 program required engineering solutions that could withstand years of global service while delivering a seamless passenger experience.

Ian Bohannon's role as Lead Mechanical Design Engineer was to develop all of the mechanical systems within the seat pod, ensuring every moving part operated flawlessly under repeated use. From reclining into a fully flat bed to securely housing entertainment systems, every mechanism needed to feel intuitive to the passenger and robust to the airline.

 

Key Systems Designed

Some of the most challenging and rewarding systems developed included:

• Telescoping Armrest – A space-saving mechanism that smoothly extends and retracts, balancing structural integrity with passenger comfort.
• Deploying Bed Extension – A robust system that transforms the seat into a fully flat bed, maintaining passenger safety while optimizing limited cabin space.
• Monitor Deployment Mechanism – An intuitive design that allows passengers to deploy and stow their personal entertainment screens securely, meeting stringent safety and certification requirements.
• Composite Structural Components – Lightweight, durable structures that reduced overall weight while maintaining rigidity, an essential factor in modern aircraft design.

 

Each of these systems required extensive prototyping, testing, and iteration, ensuring they could endure thousands of cycles without failure—all while integrating seamlessly into a luxury experience.

 

 

 

Innovation Through Collaboration

Large-scale aerospace programs demand teamwork across global suppliers, certification bodies, and design partners. Ian Bohannon's role involved collaborating with cross-functional teams spanning industrial design, ergonomics, certification engineering, and manufacturing, ensuring that our solutions not only met technical requirements but also aligned with Cathay Pacific’s brand vision.

 

Why This Matters for Our Clients

The Cathay Pacific A350 business class project demonstrates the depth of expertise we bring at I.M. Bohannon Mechanical Design. Whether designing aircraft interiors, precision mechanisms, or new product concepts, we approach every project with the same principles:

• Mechanical reliability: Ensuring every design can withstand years of real-world use.
• User-centered design: Creating intuitive and seamless experiences.

• Manufacturability: Delivering solutions optimized for efficient, scalable production.

 

This project reflects our ability to take on complex, high-stakes engineering challenges and deliver results that enhance both the end-user experience and operational performance.

 

Bringing That Expertise to You

From luxury aircraft interiors to cutting-edge consumer products, I.M. Bohannon Mechanical Design helps companies move from concept to production with confidence. If you’re developing a new product or need engineering leadership on a complex system, we can provide the expertise, tools, and processes to make it happen.

 

Let’s talk about how we can bring your next project to life.