While studying mechanical engineering at Carnegie Mellon and interning at Ford, I was given the chance to visit a supplier in Nebraska. I had one request for the rental agency at the Omaha airport: I’d like a Ford.
Keys in hand, I approached a Ford Mustang — in red.
Driving down the highway in one of America’s most iconic performance cars started me down a path I’d never imagined. Just a few years later, I’m a member of the team behind the Mustang® Dark Horse® SC convertible, the newest iteration of Mustang.
An Unexpected Path
I’ve always been a hands-on problem-solver, and I got into robotics in middle school, but I never expected to go into engineering. I honestly thought I’d be a writer.
Engineering turned out to be a great field for me. A friend steered me toward the Ford College Graduate Program, which gave me a chance to rotate through different divisions of the company and figure out where I’d be a good fit. Today, I’m a seat engineer with Ford Racing.
I’m especially proud to be part of the team that brought the new Mustang Dark Horse SC to life. It’s the first project I’ve been part of from the onset — from helping create the initial seating concepts to seeing the seats come out of production and into the vehicle.
Getting into the Driver’s Seat
Long before any of that work begins, though, our team spends time thinking about the person who ultimately sits in the driver’s seat. We have a conversation to determine: What does the customer care about? Is that driver interested in optimal features? Do they want comfort for long trips? Or do they need the grip of a seat designed for track racing?
With the Dark Horse SC, they're very possibly planning to go out to the track on weekends. That means they’ll want a lightweight, bare-bones seat that also offers them the kind of lateral support they need when they’re taking a curve at high speed.
The seats in the Dark Horse SC are designed with performance in mind. The bolstering is firmer to provide that lateral support when the car is pushing through corners, and we’ve provided extra headroom space for drivers wearing helmets on the track.
The challenge for the engineers is to make a performance seat that can keep a driver firmly planted during a turn on the track but comfortable enough for an hours-long road trip. It's a constant balancing act.
Performance Meets Freedom
With the Mustang Dark Horse SC convertible, which is the first new high-performance Mustang convertible in more than a decade, that balance of performance and comfort is top of mind.
The open-air Mustang pairs a supercharged 5.2-liter V8 producing 795 horsepower1 and 660 lb.-ft. of torque with a seven-speed dual-clutch transmission. It also has a specially tuned next-generation MagneRide suspension that delivers a smooth ride while cruising and a planted feel when the driver takes a curve or leans into the accelerator to make a pass.
With the twist of a handle and the touch of a button, the roof drops, opening the cabin to the sky — and to the unmistakable sound of the supercharged V8.
More than a Place to Sit
Like most people, I hadn’t thought much about seating before joining Ford, even though it’s the part of the car used perhaps more than any other.
Early in my career, I spent time at manufacturing facilities, watching seats being assembled and inspected. I learned how decisions made early in the design process play out in the final product. Now, I work to anticipate potential manufacturing or quality concerns before they become issues in production.
Seats are surprisingly complex. It’s one of the only parts of the vehicle where engineers are thinking about critical safety features, comfort, and appearance. Color and materials matter just as much as the engineering because it all has to work together while looking good.
How a fabric moves or stretches has a big impact on the mechanics of a seat. How a customer feels opening the door, sitting down, and hitting the start button are all influenced by the seat, even if they don’t know it. From comfort to color, all the details matter.
For the convertible, we have two interior colors, Space Grey and Black Onyx. Before seeing it in person, I preferred the Black Onyx seats, but I've been converted to a Space Grey fan: I think that the light seats pop nicely against a darker exterior, especially with the top down. Depending on whether a customer wants features like heating, cooling, memory, or massage, a seat can have hundreds of parts.
Engineers also need to think about the variety of drivers who get behind the wheel. What is considered a comfortable seat is entirely subjective. We gather feedback from people with different body types and driving experiences, looking for the sweet spot between support and comfort.
Seats really only draw someone’s attention when there’s a problem. If engineers like me have done our job right, you’ll never have to think about all that went into the creation of that seat.
I recently went on a road trip across the Colorado Rockies, which is one of the most beautiful stretches of highway in the country. The feeling I get out there, being out in nature on these winding scenic roads, is one that can really be enhanced depending on the vehicle you’re driving. I can’t help but think a road like that would be an ideal way to experience the Dark Horse SC convertible.
I see this vehicle as a perfect companion for that kind of drive. It has the sort of flexibility that is at the core of how we’re designing for the Mustang customer.
The Dark Horse SC coupe can be a performance machine, but it doesn't have to be confined to the track. It can be a daily driver, a road-trip car, or a weekend escape. The convertible, meanwhile, is designed to give drivers the freedom of the open road.
Taking a Generational Brand Forward
That is part of the Mustang's enduring appeal. It’s an incredible legacy. I'm so proud to be part of Ford Racing and part of a team that's pushing the envelope on design.
“I'm so proud to be part of a team that's pushing the envelope on design.”Diya Nuxoll, seating engineer for Ford Racing
I lucked out landing on the Ford Racing team, getting to work on complex engineering problems with a really, really smart group of people. I feel fortunate to be in a group that is so intent on delivering new and innovative solutions for a brand with such an enduring and empowering legacy.
A few years ago, I was a young engineering student picking up a red Mustang at an airport. Today, I’m designing the essentials of where the next generation of Mustang drivers will sit.
Diya Nuxoll is a seating engineer for the Ford Racing team.
1Horsepower and torque ratings based on premium fuel per SAE J1349® standard. Your results may vary.
