During manufacturing, the foam is deformed in certain areas, particularly on the bolsters at geometric curves, due to the upholstery. This deformation leads to undesirable deviations from the intended Design-A-Surface. To minimize these deviations, the foam geometry must be selectively increased. It is crucial to determine where and to what extent adjustments are needed to achieve the Design-A-Surface in the finished seat.

By adding extra foam, the seat cover can be stretched more tightly and consistently over the surface. This leads to fewer wrinkles, producing a smooth and visually appealing result. A tighter fit also enhances the seat's ergonomics by ensuring the cover conforms closely to the foam's contours. This alignment provides better support and comfort, optimizing the seating experience for the user and improving both form and function.

Foams naturally compress and lose volume over time due to continuous use and the effects of aging. Incorporating a small additional geometric overbuild helps counteract this issue. The extra foam layer serves as a protective buffer, helping to maintain the seat's original shape and firmness. This prolongs the seat's lifespan, ensuring it retains consistent comfort and structural integrity over a more extended period.