By Andrew Sink, Staff Applications Engineer, Carbon
For a long time, when it came to designing saddles for bikes, striking a balance between comfort, performance and durability has been the goal. However, meeting these objectives has come with limitations, mainly insofar as the materials used.
Foam and molded materials for saddles, such as plastic, were widely used for their durability and affordability but often failed to deliver personalized support and long-term resilience. Poorly designed saddles can lead to discomfort, numbness, poor posture, lower back pain and even potential injury due to bad pressure distribution on sensitive areas, driving the demand for seating that is comfortable, durable and increasingly personalized to the individual.
3D printing/additive manufacturing is disrupting this application area, offering new possibilities of customization, efficiency and innovation which were not previously attainable. By designing lattice structures that offer precise pressure distribution, brands are demonstrating that the future of saddles lies in 3D printing technology.
Leading brands are taking to 3D printing to reimagine their saddle designs. These companies include the likes of US bicycle manufacturer, Specialized, whose award-winning S-Works Power with Mirror Technology has received rave reviews from cycling enthusiasts.
Demonstrating the capabilities of Digital Light Synthesis™ (DLS) 3D printing technology, the S-Works Power Saddle with Mirror comprises a complex multizonal lattice structure designed for optimal pressure relief and comfort. Proving the scalability of the technology, that particular saddle has since paved the way for the introduction of the S-Works Romin Evo with Mirror, which was specially developed for the performance cycling market. Thanks to the flexibility of the DLS technology deployed to develop this saddle, the project took just six months from prototype to commercialization.
Similarly, Italian biking accessory brand, Fizik, has a solid track record of using technology and data to create revolutionary products that elevate the rider experience.
Having successfully leveraged elastomeric materials, lattice design software and DLS 3D printing technology, the company recently set itself the challenge of harnessing the same technology to develop a fully customized 3D printed saddle topper that would provide maximum support, stability, and comfort, minimizing pressure points and enhancing aerodynamic efficiency.
Collaborating with pressure map data experts at gebioMized, Fizik engineered a system for collecting pressure map data (specifically the body force transferred to the saddle as well as how that force is distributed across the saddle’s surface) from riders to customize a saddle design with distinctive zonal cushioning tuned to adapt specifically to the rider’s body. This data is subsequently translated into the 3D printed lattice structure using Carbon Custom Production Software, resulting in a highly personalized supportive saddle optimized for comfort and performance.
The Saddle of Champions
By capitalizing on the flexibility of 3D printing, the company was granted the means to very quickly and cost-effectively develop individually designed one-off saddle paddings. The result is Fizik’s recently launched, fully customized, 3D printed One-to-One saddle, now in use by professional riders like Tadej Pogačar who, in February this year, rode his personalized Aeris LD One-to-One saddle as he sealed victory on the 2025 UAE Tour.
Another brand to have firmly embraced 3D printing technology to revolutionize its design to production workflow is saddle manufacturer, Selle Italia. To meet the highest levels of performance that its elite cyclists required, Selle Italia wanted to find a material that was not only supportive for riders but was also breathable and ultimately provided a more comfortable ride. Requirements included:
● Multiple zones within the saddle space to optimize performance and comfort
● Energy-returning elastomeric material that was both soft and grippy
● High breathability
● Increased comfort for the rider
● Ease of printability with difficult shapes
Working closely with Carbon production partner, Prototek, Selle Italia was recommended EPU 41 material – a durable, highly elastomeric, energy-returning material that offers cushioning and gripping for the rider. This particular material also lends itself to multi-zonal lattice designs that are extremely breathable and can be tuned precisely to offer a variety of mechanical responses for an overall better ride.
The company has since expanded its 3D printed line to include those for performance cycling, comfort cycling, and triathlons – the first ever made with 3D printing and developed in partnership with reigning men’s IRONMAN World Champion Patrick Lange.
The utilization of 3D printing by industry leading brands such as Specialized, Fizik and Selle Italia, and the revolutionary saddle designs that they are able to realize, is indicative of the transformative nature of this technology. Not only does it successfully address long-standing challenges in rider comfort but also sets the standard for future innovations and increased customization to suit the individual. As companies like Carbon continue to innovate their technology offering, it paves the way for even greater product design innovation among brands like these and many others.
