Tag Archives: saddle

This 3D-Printed Saddle Is Designed Around the Horse, Not Adjusted to It

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A saddle is one of the most intimate pieces of equipment in equestrian sport. It sits at the exact point where two athletes meet, translating weight, movement, balance, and intention between horse and rider. Yet for something so central to that relationship, saddle fitting has remained surprisingly dependent on traditional measuring methods, adjustment, and compromise. Catalyst asks what happens when that process becomes precise enough to design around the individual horse from the beginning.

Designed by Hallie Eskey, Catalyst is a custom-fit, 3D-printed jumping saddle developed specifically for the demands of show jumping. The sport subjects both horse and rider to repeated impact as they accelerate, take off, land, and immediately reorganize their balance for the next obstacle. In that environment, the saddle has to do far more than simply provide a seat. Poor fit can create pressure, discomfort, and injury for the horse while interfering with the subtle communication between horse and rider. Catalyst approaches the saddle as performance equipment shaped by anatomy rather than a standardized object that the body must adapt to.

Designer: Hallie Eskey

The process begins with LiDAR 3D scanning. Instead of relying solely on manual measurements of the horse’s back, the horse is digitally captured and brought into CAD software. That information becomes the basis for a parametric lattice structure modeled specifically around the horse’s curves. The result is a level of customization that would be difficult to achieve through conventional hand measuring alone.

That lattice is also Catalyst’s most recognizable visual feature. Rather than hiding its internal structure beneath layers of material, the saddle leaves its carbon fiber geometry exposed. It gives the object an almost architectural quality. The pattern is not there simply to make Catalyst look futuristic. Carbon fiber allows the structure to remain lightweight while providing shock absorption, addressing two qualities that become especially important when horse and rider are repeatedly experiencing the force of landing.

There is something compelling about seeing a product associated with centuries of tradition adopt a visual language that feels closer to computational design, performance footwear, or aerospace engineering. Yet Catalyst does not attempt to erase the craft associated with saddle making. Leather remains part of the object, and traditional leather craft was incorporated into the development of the project. The result sits somewhere between artisan practice and digital fabrication, allowing each to solve the problems it handles best.

The same thinking extends into the way Catalyst is assembled. The saddle is designed around a reduced number of components, with rivets used in place of synthetic adhesives. This makes the construction easier to disassemble, repair, and replace in parts rather than treating the saddle as a permanently bonded object. It is a quieter approach to sustainability than simply changing materials. Instead, longevity is designed into the architecture of the product itself.

That consideration is particularly relevant for highly specialized sporting equipment. Performance products tend to sit in an uncomfortable space between durability and technological progression. They need to withstand demanding use, yet improvements in materials and manufacturing continually push them forward. Designing components that can be separated and replaced gives Catalyst a way to accommodate both realities.

The final saddle grew out of a 20-week development process that included research with equestrian professionals, saddle teardowns, detailed sketching, two full-scale prototypes, iterative CAD modeling, and parametric development in Grasshopper. Those stages matter because Catalyst could easily have become an exercise in applying an impressive manufacturing technology to a familiar object. Instead, the technology follows the actual constraints of the sport and the anatomy of the animal.

Perhaps the most interesting thing about Catalyst is that its innovation begins with fit rather than form. The striking lattice and contemporary silhouette are consequences of rethinking how a saddle can be made, adjusted, repaired, and individualized. 3D scanning allows the horse to become the starting geometry. 3D printing allows that geometry to become physical. Carbon fiber responds to weight and impact. Riveted construction considers what happens when the product eventually needs attention.

Catalyst suggests a different future for equestrian equipment, one where customization does not depend entirely on adjustment after manufacturing. Instead, the individual horse can inform the object before it is made. For a sport built around communication between two bodies, designing the equipment around those bodies feels less like a technological spectacle and more like a logical next step.

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The Bike Saddle 3D-Printed and Hand-Stitched in France

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Most conversations about technology and craft follow the same script. Technology is fast, scalable, cold. Craft is slow, precious, warm. The two might share a showroom floor or a mood board, but they rarely share a philosophy. Mahdi Naïm’s AERIS bicycle saddle disagrees with that entire premise, and the disagreement is worth paying attention to.

AERIS is not a bicycle saddle that happens to look interesting. It is a bicycle saddle built around a single, demanding question: what if 3D printing and traditional craft weren’t layered on top of each other, but designed together from the very first sketch? That shift in thinking, from assembly to co-authorship, is what separates AERIS from the dozen other “tech meets heritage” products that surface at design fairs every season.

Designer: Mahdi Naim

The structure is built on a lattice produced through high-precision photopolymerization, specifically SLA and DLP printing, in high-performance elastomer resin. The geometry is not decorative. It is functional in the most literal sense: the lattice density changes across three zones of the saddle, denser where firm support is needed under an aerodynamic riding position, progressively softer through the transition zone, and open at the perineal relief zone to minimize pressure. No foam. No padding added to compensate for poor design thinking. The structure itself is the comfort system.

That kind of discipline is rare, and I say that as someone who has watched a lot of product design lean on material additions to solve problems that should have been solved earlier. Foam is easy. Getting the geometry right from the start is not. It takes conviction to design without a fallback.

The second layer, and I do mean the second design logic rather than a second material slapped on afterward, is where a French master saddler comes in. Full-grain vegetable-tanned leather, hand-stitched. The studio is clear that this is not an aesthetic decision. The leather works mechanically with the resin, distributing pressure and shear forces in ways that neither foam nor synthetic materials can match at equivalent weight. The interface between the two materials was designed during the modelling phase, not decided once the print came out of the machine.

This is the part I keep coming back to. The leather isn’t a finish. It isn’t branding. It is the second structural argument in the same conversation, and the conversation started before any material was touched. That level of intentionality is genuinely unusual, even among products that wear the word “craft” proudly on their labels.

Mahdi Naïm himself is worth knowing, if you don’t already. He is an industrial designer, a Grand Maître Artisan, and a German Design Award laureate who runs his studio between Lyon and Casablanca. His practice sits at the intersection of French engineering and Moroccan craftsmanship, and AERIS reads like a project that could only come from someone fluent in both languages. The saddle doesn’t feel like a technology demonstration with craft applied on top, or a heritage object with a 3D-printed frame underneath. It feels like one object, made by two disciplines that had to agree on every decision before anything was built.

AERIS is still in active development and moving toward small-series production. The studio is in conversation with industrial partners in additive manufacturing and premium cycling. That means this isn’t a concept in the gallery-piece sense, displayed under glass and admired from a distance. It is a product that intends to be ridden.

Whether you cycle or not, whether you follow product design closely or just occasionally land on something that makes you stop scrolling, AERIS is the kind of object that rewards a second look. Not because it is visually striking, though it is, but because the thinking behind it is genuinely coherent. The lattice, the leather, the hand-stitching, the parametric modelling: none of it is decoration. All of it is argument. That is harder to pull off than it looks, and considerably rarer than the design world likes to admit.

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Genius Two-Part Saddle moves as you bicycle to let you go long distances without soreness

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The excitement of learning to ride a bicycle came with the realization that the more time you rode the more pain was inflicted on the butts. Yes, those days of early riding were all about non-stop riding the bike as speeds increased with every confidence boost, and the consequent sore rear by the end of the day.

To keep any bicycle true to the basics and long-lasting, the saddle has to be firm and contoured for maximum comfort. That however is counterintuitive as the seat can be uncomfortable during long rides. The solution is to prevent the body part from being pushed against a stationary support surface. How do you do that? With a movable saddle mechanism that doesn’t strain your butts. Thank god!

Designer: ataraxyBSC

The story of this unique bike saddle’s development started with the idea of a compliant bicycle seat in 2016 by Australian engineer Robin Macan. Sometime after that, he met with industrial designer Philippe Guichard to take things further and create a two-part bicycle saddle that makes it ultra-comfortable for riders no matter the length of time they paddle. This ultimately led to the partnership with Melbourne-based Whistle Design Group to take the vision further and develop an actual product.

Macan finally created his startup ataraxyBSC to solve the problem of a pain-inducing bicycle saddle that’s been left in the shadow for decades. The solution is the vabsRider bicycle saddle with a split seat design. This simple yet clever saddle moves with the movement of legs, rotating around the hip joints to eliminate any pressure-inducing surface contact. Both the sides move independently with the leg movement, transferring pressure from the sit bones to the femurs, This creates a balanced load distribution, and gone are the sore muscles when bicycling for long hours at a stretch.

The user can further adjust the fore/aft and height, or toggle the angle or width of the saddle. The latter I’ve always wondered why no one thought about before. There’s no word about the pricing or availability of the vabsRider bicycle saddle, but you can express your willingness as an early adopter by emailing ataraxyBSC.

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Cork bike saddle amplifies the eco-friendly quotient of your ride

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There was a huge increase in bicycles and all biking accessories during the pandemic as people tried to find alternative means of transportation. Now that we’re almost back to whatever normal is, bikers are still a huge segment of the transportation market for a lot of reasons. One of these is that it’s more eco-friendly that cars since it does not use any fuel. But there has also been an interest in making the bicycles themselves even more eco-friendly.

Designer: Frame Cycles

One new product that can make your bike more sustainable is the FR-1 Bike Saddle since it is made from reconstituted cork and grade 5 titanium. It was able to do away with the usual three plastic layers of the bike saddle and replace it with the single piece of cork. What’s more, this cork is able to have all the properties of those plastic layers: structural rigidity, foam comfort, and weather resistance.

According to Frame Cycles, they were able to create the first batch of these cork saddles by using a firm grade of reconstituted cork so it has the similar hardness to the usual leather bike saddle. This also means that you will have to spend at least two weeks for the cork saddle to break in and start to soften. They will eventually release variants with different grades of cork. The process of sourcing the materials from the cork trees is also less harmful as stripping the bark every 8-10 years boosts the carbon consumption 3-5 times.

Before the cork saddle gets to you, the components are harvested in Portugal and then molded when it reaches Glasgow, Scotland. This is also where the parts are treated with water-based lacquer and then integrated into the welded titanium substructure. Knowing this entire process, it will not surprise you that the FR-1 Bike Saddle is a bit expensive at around $130. But of course, it’s a small (expensive) price to pay if you want a more eco-friendly bike to accompany your sustainable lifestyle.

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