Skip to content 
When designing an electric vehicle, seat architecture might not be the first place you expect a hefty cost burden. Yet in the KIA EV9, it just might be. At Munro & Associates, our latest teardown dives deep into the KIA EV9 seat design to uncover the balance—or imbalance—between style, function, and cost. This KIA EV9 seat analysis is more than just foam and fabric. It’s a lens into how design decisions ripple across manufacturing and customer value.
Let’s break it down.
Seat Structure: More Than a Place to Sit
Seats serve three essential roles: comfort, safety, and style. The EV9’s seats tick all those boxes, but at what cost?
The seat must withstand crash forces and secure the occupant. That’s non-negotiable. But styling decisions—especially when they demand structural rework—can spiral costs quickly. In the EV9, style-forward choices like custom headrests, complex seat backs, and powered calf rests introduce extra brackets, wiring, and stitching. Each choice cascades into increased manufacturing, handling, and engineering complexity.
Form vs Function: A Tale of Three Headrests
Take the front-row mesh headrests, for example. They look airy and modern, but require a highly involved construction:
- Reinforced internal structures for mounting
- Custom airy foam overlays
- Fabric skins with retaining rings
That’s roughly $3–$5 more per headrest, or $15 per vehicle when you include overhead and profit.
In the second row, Kia adds a hugging headrest with flexible sides. It barely moves but still requires:
- Hinged molded mechanisms
- Extra sewing for retention
- A more complex foam and cover assembly
Despite offering limited ergonomic benefit, it likely costs even more than the front-row version.
So here’s the real question: would a customer knowingly pay an extra $30–$40 for fancier headrests?
The Hidden Cost of Style-Driven Engineering
One standout example is the back panel of the front seat. Rather than a standard flush surface, the EV9 features a raised, molded back that doubles as a handle. Executing this required:
- A MIG-welded bracket
- Multiple panel components
- Extra fasteners and finishing
This “design-forward” execution costs around $15 per vehicle, and applies to both front seats. That’s another $30 purely for aesthetic differentiation.
This isn’t uncommon. At many OEMs, design studios push form without fully understanding the downstream cost. By the time it reaches engineering, the directive is to “make it work”—even if that means higher part counts, tooling, and complexity.
Comparing Structures: Hyundai Ioniq 5 vs KIA EV9
The seat frame reveals more cost insight. Hyundai’s Ioniq 5 frame uses laser welding in a robotic cell—efficient, precise, and repeatable. Kia’s EV9, despite sharing platform DNA, swaps in MIG welding for many joints. This suggests either a transition in process or a move away from high-efficiency joining.
Differences in hole placements and stamping tweaks suggest ongoing development. But it begs the question: why not standardize if the core structure is shared?
Calf Rests: Heavy and Under-Tuned
The powered calf rest in the front row is another cost driver. Though it improves passenger comfort, it’s built from:
- Heavy welded steel assemblies
- Foam inserts
- Motorized actuation hardware
This feature may cost $30–$40 per seat, with little sign of lightweight optimization. It appears Kia prioritized function over tuning, likely due to its low adoption rate. But without efficiency tuning, features like this become dead weight—literally and financially.
Second Row Surprise: Bigger, Costlier
Despite common assumptions, the second row is larger and more complex than the front. It lacks a footwell, so the structure is taller. It includes power features and shares the same calf rest. On top of that, its headrest is the most intricate yet, combining movement, wrapping sides, and extra mechanical pieces—all for questionable ergonomic value.
Third Row Reality: Small But Expensive
The EV9’s third row defies expectations. It’s tight and uncomfortable—typical for a three-row SUV—but surprisingly expensive to build. Why?
- Thicker steel: Supports folding and hinge strength
- Folding headrests: Require spring and cable assemblies
- Dual cable releases: Enable folding from both second-row and trunk
- Spring-loaded leg retraction: A clock spring releases the seat base forward after latch disengagement
Despite being the least comfortable, it’s arguably the most mechanically involved. You’re paying for complexity in a place most adults won’t want to sit.
Load Floor Innovation: Finally, a Win
Among the cost-heavy features, there’s one lean design bright spot: the load floor.
Rather than thick injection-molded panels or stamped steel, Kia uses:
- Die-cut corrugated plastic
- Simple wire structures
- Fabric covering
This solution is cheap, modular, and effective. Originally met with skepticism, it’s proven resilient and ideal for rear-seat folding mechanisms. Better yet, it avoids hard materials that could pose a hazard in the third row.
Cost Creep Adds Up Fast
If you add the following:
- Fancy headrests (front and second row): ~$30–$45
- Decorative back panels: ~$30
- Calf rests: ~$60–$80
- Cable actuators and hinges: ~$40–$50
You’re potentially looking at $150–$200 per vehicle just in “value-added” seat features.
Now scale that across production. Multiply by 100,000 vehicles, and you’ve just spent $20 million more on seat features—many of which don’t increase safety or comfort in a measurable way.
Final Thoughts: Where Do You Want the Money?
Kia’s EV9 seat teardown showcases the silent killer of vehicle profitability: feature creep. While none of these components individually break the bank, they collectively shape cost structure, margin, and price.
So ask yourself: as an EV buyer, do you want your money spent on:
- Flashy seat styling?
- Extra comfort features?
- Battery range?
- Performance?
- Exterior curb appeal?
The interior is where you spend your time—but only you can decide if the premium features are worth the premium price.
Like Our KIA EV9 Seat Analysis?
If you’re serious about design, teardown analysis, or cost optimization, dive deeper with Munro & Associates. Watch the full EV9 seat teardown and explore more expert breakdowns at Munro Live—where insight meets innovation.