3d printed saddles, what’s in it for me? and should I upgrade?

If you haven’t had the need to buy a saddle in the last few years then you might not be aware of the new boy in town… 3D printing… I get it, I get it. You have had your saddle for a long time, you like the way it fits and the style you can set it up perfectly between bikes. For years this was a legitimate reason for passing on an upgrade, then 3d printed entered the chat.

At first we all drooled at sexy pictures of lattice structures, cool photography and the 3d printed word banded around the media. At a time when 3d printers were hyped and 3d printing became a common word, with our kids asking for printers at home and elite engineers waxing the lyrically of faster prototyping and better performance…

Let’s back up…

• Whats all the fuss? (the tech)
• Under Pressure
• Why are they so expensive… isn’t 3d printing cheaper?
• Photo Gallery
• Testing
• Should you buy a 3d printed saddle?
• Why I chose Salle Italia

What’s all the fuss?

Engineering perspective, regular saddles are plastic or carbon base plinths with layers of different density foam glued together under a skin and either carbon or metal rails, 3d saddles are plastic plinths which are then located inside a 3d printer which uses a computer controlled nozzle to melts strands of flexible plastic in the shape of a saddle. This creates a controllable “weave” of “mesh” like surface which is very indicative of 3d printing. This mesh eliminates the need for foam and traditional support materials.

If we look at the basic needs the “make up” or construction of a saddle is important to deliver Support, Stiffness and Cushioning, all in exactly the right places. Combined on a shape that fits well under your bum and legs.
The biggest advantage of the tech is that 3d printing is the “exactly” part, being precisely controllable, meaning cushioning can be controlled down to the millimeter both in terms of location and density. The filament technology combined with the shapes of the mesh, means the density can be acuratley build to a very specific need. Very specific… location and density. This in itself is a step beyond traditional foam and fabric.

Comparison

	3d printed saddle	Traditional saddle
Price	$350+	$150, 200, $300
Material	Plastic and carbon for base, PLA and Nylon filament for top of saddle	Plastic, carbon PU Foam, Silicone Gel, various surface materils
Cushioning	3d print – precise location of density	foam -less accuracy in cushioning,
	precise manufacture of density and dual layers in Salle Italia	more variation in foam density
Breathability	more breathable due to mesh
Pressure Distribution	more adaptive to a range of fits	very fit dependent
Shape	many widths and shape profiles	many widths and shape profiles
Cut Outs	no cutouts, large cut outs , extra large	no cutouts, large cut outs , extra large
Weight	130 grams upwards, the one I tested was 208grams Novus
Accessory Mounts	2x m4 bolts at rear	dependant on specific model

Under Pressure

How can 3d printing help?
The human body is unique, then throw on top of that suspending yourself on a bike for hours on end. Well, as far as saddles go, comfort has a lot to do with pressure on the body and that can be measured on the saddle by some advanced tech.The key here is distribution of pressure.

GebioMized pressure mapping allows measuring of pressure zones and allows manufacturers to design better saddles. 3D Printing provides control by manufacturers to literally and specifically design where a saddle is soft and hard down to 0.5mm location. Along with the benefit of control to define many various densities in specific locations. Cushioning and location control.

Isn’t 3d printing cheaper -so why are they more expensive?

3d Printed saddles are typically 15-25% more in price. A top of the line foam saddle maybe around $300 while the equivalent position 3d printed one is about $400. Generally speaking we have been lead to believe that 3D Printed things are cheaper due to the logic of labor free automation, but in a lot of optimized manufacturing cases this is the opposite where the cost of a 3d article is machine time which is actually expensive. Generally a 3d top part of the saddle will take about 5hrs to print. Then theres the amortization of expensive and accurate 3d printers and of course the material. A traditional saddle maybe more labor intensive, but the operation and manufacture is much quicker and has been optimized over the years.

Selle Italia Novus Evo Boost – Gallery

Testing

I have ridden the Salle Italia Novus Boost Saddle saddle for over 400 miles, and coming from a well fitting traditional foam and plastic saddle with a similar shape I can say the change in comfort alone is transformative and the first large thing I noticed. The second thing that I didn’t notice was rubbing, the wings and width of nose are designed well. Normally if these are off you will notice chaffing on longer rides where your thighs are interfering with the rear wings or the sides of the front of the nose.

Dual density technology, aka padding. It feels soft when you need and supportive at the same time. This is enabled by the 3d printing and build of thicker fibres / filament structure, Selle Italia have a dual density system where they specifically print a lower denser mesh and a more supple and tailored lighter on top.

Saddle fit was important and I was careful to evaluate my fit factors of shape and width ensuring that my match was close to my fitted position on the old saddle. Thus the choice to go with a wavy saddle, your may differ, but the 3d printed technology remains the same.

Durability – The tech has been around for a while now, and all the larger brands have some 3d printed models. Some more successful than others, but generally all the mechanical kinks have been worked out. Even now I see a lot more variety of shapes from Flat to wavy in different widths.

Should you buy a 3d printed saddle?

Racer / High milage rider – If you ride a lot of hours and consider yourself a cyclist then you should consider this as a performance upgrade as you will definitely reap the benefits of a 3d printed saddles in weight and comfort.

Experienced cyclist – If you are an matured / experienced cyclist who hasn’t purchased a saddle in a while because you know what you like and what works, (don’t worry, I am this person) these are worth a look, as they can unlock a greater level comfort , keeping you on the bike longer or just more pleasurable.

Fussy or problematic fit – If you have always had issues with saddles and fit this new tech will unlock new levels. The adaptive fit due to precision and layering of 3d printing delivers adaptive support where traditional saddles cannot.

Sweaty bum rider – I noticed that due to how they are made, the inherant properties of the weave, 3d printed saddle feel cooler and more ventilated. This stands to reason over layers of foam and none breathable materials. So if you are having issues with a hot bum! this tech will be for you!

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