​The HB-1 seat stands out in the plastics industry for its sophisticated design and the challenges of forming its material. Created by Magic Vac Inc. for Huckleberry Hiking’s Cascade Tandem Hiking Cart, this critical component combines advanced 3D-printed tooling, complex geometry, and thermoplastic polyolefin (TPO) selected to balance outdoor durability with passenger comfort. The project earned Magic Vac Inc. the Silver award in the Production Parts from 3D-Printed Tooling category at the 2025 SPE (Society of Plastics Engineers) Thermoforming Conference.

 

Awards aside, why we love the HB-1 seat and the Cascade Tandem Hiking Cart:

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It helps families keep exploring together. Huckleberry Hiking founder LJ Wilde developed the cart after his daughter Luci, who has a rare genetic disorder, outgrew the backpack carrier that allowed her to join family hikes. His determination to keep her on the trail became a thoughtful solution for other families facing similar barriers.

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Designed for singletrack trails, sand, and snow, the Cascade Cart keeps approximately 75% of the combined cart and passenger weight on its wheel, reducing the load carried by the accompanying hiker. Suspension and a padded molded seat help soften the ride, while four reclining positions, a four-point harness, and an integrated seat pommel support passenger positioning. A mechanical disc brake provides control on descents, and the folding frame makes transportation easier. These details give families more opportunities to experience the outdoors together.

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For us at Magic Vac, that purpose gives the manufacturing challenge meaning. Every complex contour and carefully formed detail contributes to a seat built for comfort and demanding outdoor use. We’re proud to help turn an inventive idea into shared adventures and family memories.

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