Form Cycling Accelerates Development and Production of New 3D Printed Saddle

Form Cycling is manufacturing their new 3D printed saddle padding with the LuxCreo Smart Factory to overcome supply chain challenges and accelerate development times. Using 3D printing gives Form Cycling a rapid way to iterate saddle designs locally, and once finalized, replicate manufacturing success.

“We could not get full saddles manufactured for at least 18 months,” said Kevin Bailey, bike fitting specialist and owner of 3D Bike Fit and partner at Form Cycling. “Now we are 3D printing the saddle padding locally, testing it in the field, making design adjustments, and reprinting it all within days.”

Form Cycling designs their saddles leveraging years of experience bike fitting cyclists with advanced systems at 3D Bike Fit, well known in Silicon Valley, with a deep understanding of the human body and biomechanics.

“With 3D printing, we can easily design and make a bike saddle that targets specific pressure zones by changing the density or structure of the material – that you cannot do with foam,” said Ernesto Calderin, partner at Form Cycling.

Recent advancements in 3D printable elastic resins are further enhancing product performance. Form Cycling is 3D printing complex structures with high performing elastic resin for a saddle with better shock absorption.

“When I went off-roading, the 3D printed saddle absorbed shock better,” said Cesar Correa, senior bike fitting specialist at 3D Bike Fit and partner at Form Cycling. “With foam saddles, it compresses and stays, whereas the 3D printed saddle continues to absorb the shocks – sustaining the high performance and providing a more comfortable ride.”

For Form Cycling, the future of 3D printing is customization of saddles for each cyclist. As shortages continue to affect many industries, 3D printing Smart Factories will become essential to address demand and mitigate supply chain disruptions.

Form Cycling’s new 3D printed shock absorbing saddle is planned for availability in Q4 2021.