We’ve seen a bunch of seats blow out all of a sudden due to inexplicable weld failures.
General Announcement: SEATS THAT RIP OR HAVE WELD FAILURE IN NORMAL & REASONABLE USE ARE WARRANTEED. Send 'em in, we’ll replace them.
The seat gremlins attack, again!
Moving on to your questions:
It’s just a welded prayer seam. You can iron it, but it won’t be as strong as a proper weld. If you iron it for immediate use, feel free to send it in w/ a note for replacement once you’ve got the down time.
The seat should (and generally is not) as fragile as you’ve experienced. True, it’s comparatively light weight, but when the process goes properly, it generally lasts for years without problems. Last year, Alpacka had a major series of defective seats, which we replaced for anyone who let us know they had one. We did some tech & materials changes, and it was great… then suddenly, we’ve seen a spate of bad ones. They seem to be the most difficult part to build consistently, which was big impetus for making them removable. That, and in really hard use they are easier to blow out.
On inflation: generally, our best observation is that a fully inflated seat is fine as long as you’re not (a) really boating hard on it, or (b) don’t leave it out in the hot sun (where thermal expansion will stress the prayer seam).
I believe Sheri (our inventor) has built “tough drawers” in a few instances, but you’re correct there’s no product detail on it right now. They were unofficial custom jobs.