This was just the starting point of a long, challenging journey. To replace a metal housing with plastic could not meet the requirements. We contemplated several approaches, including those that fell into categories like “cannot work” and “doesn’t exist.” It became apparent that the idea with the highest potential was mission impossible for a knee airbag — to replace the housing with fabric!
This required a totally new generation of knee bag design, as well as specialized processes and manufacturing equipment that differed from the traditional technology employing steel housing designs.