The fact that 3D saddles have finally arrived in the professional peloton was impressively demonstrated at the Tour de France 2025. Hardly any other technology trend was as present in the peloton as the open-structured, 3D-printed seat surfaces. Even absolute top stars are now using them: Tadej Pogačar rides the 3D model Vento Argo R3 Adaptive from Fizik, while Red Bull pros Remco Evenepoel and Florian Lipowitz rely on 3D saddles from Specialized. Evenepoel relies on the top model S-Works Power with mirror technology, Lipowitz on the Romin Evo with mirror. Like Evenepoel, Nico Denz also rides the S-Works Power with Mirror.
The Specialised saddle from Nico Denz
In December, we spoke to the German pro about his 3D saddle at the Red Bull-BORA-hansgrohe team presentation in Mallorca. Denz didn't want to reveal much, just this much: he had previously ridden a classic production model with foam padding, but had developed seating problems. On the recommendation of a Specialized saddle specialist and based on data from test rides with a pressure measuring film on various saddle models, Denz switched to the 3D version - and has apparently had no complaints since then. Tadej Pocacar's Fizik saddle could be a custom-made saddle, as Fizik offers the One-to-One custom programme. However, when we asked the manufacturer and outfitter, nobody wanted to confirm this.
Since the first 3D series saddle from Specialized, this manufacturing technology has developed from an exotic high-tech trend to a large market with an initially small selection of models. The best-known players in this segment now include the who's who of the saddle industry. Shortly after Specialized, Selle Italia and Fizik followed with well-known models such as the SLR or the Antares; today, almost every model is also available as a 3D version. Prologo debuted with its Scratch and Nago models at the beginning of the 2025 season with the characteristically perforated saddle cover. The saddle brand Repente, also from Italy, has a brand new printer. Their Nomad 3D model features a white saddle cover instead of a black one. Shimano's own brand Pro has announced the Stealth 3D Saddle model for the beginning of January. A specially developed smartphone app with various selection criteria is designed to help you choose the right saddle.
Big Player
The 3D printing specialist Carbon from the United States is a driving force behind the market conquest. The tech company from California builds the printers that Specialized, Selle Italia and Fizik use to manufacture their saddles. The company recently raised 60 million dollars (around 50 million euros) in new capital to expand its role as a pacesetter in the digital manufacturing sector. The Americans print using the stereolithography process, in which a liquid photopolymer hardens layer by layer with the help of a laser, making complex structures with different hardening zones possible. Incidentally, the Californian neighbour Specialized has negotiated an exclusive right in the collaboration with Carbon: only the "Mirror" saddles have an almost closed saddle cover instead of an open-pore saddle cover like the competitor models - for a handful of dollars more. As the market grows, extremely affordable 3D saddles are also appearing on platforms such as AliExpress. Brands such as Ryet entice customers with prices starting at 50 euros. What sounds tempting should be viewed critically: There is often no information on width, shape or material, and there are also doubts about durability and product safety. This is a risk for a component with direct physical contact and high loads.
Custom made as an opportunity
Apart from Fizik, which also offers individually manufactured one-offs with its One-to-One programme, the major competitors Specialized and Selle Italia only market 3D series models whose shape corresponds to well-known classic models with foam padding. One of the reasons given by Specialized years ago was that customised saddles could not be "commercialised", i.e. marketed profitably (TOUR 7-2024, Druckpunkt).
Where the saddle giants see no market, small suppliers find their niche. The well-known manufacturer Posedla has been in business as a custom supplier for several years. Customised production according to individual specifications is the Czechs' speciality. Personal data such as weight, position on the bike or intended use plus a personal imprint on their "Smiling Butt Kit", a foam cushion with a permanent imprint of the buttocks, serve as the basis for the print data for the customised saddle. This complete service costs around 500 euros and the "Joyseat" arrives at home by post after around six weeks.
Fingerprint Cycling prints the complete saddle
The German company Fingerprint Cycling, another supplier of customised printed saddles, works on a similar principle. The head and founder of the young company from Kleinblittersdorf in Saarland is Clemens Schwöbel. The mechanical engineer is a keen cyclist, rode his first bike race at the age of six and had: constant seat complaints. Long story short: during his studies, the keen cyclist learnt about 3D printing; four years ago, he designed his first prototype, which he now sells together with his still small team of five as the FPS-Neo model.
This is created on the basis of a questionnaire and two impressions in two foam pads in two different positions. How this data is modelled into a saddle shape by the printer remains a company secret. Just this much: Schwöbel wrote the programme himself and the saddles are produced in-house with a small but constantly growing printer farm. Both the saddle shell and the padding are produced within six to ten hours using the layer printing process. At a price of "only" 359 euros, the FPS-Neo customised saddle from Saarland is comparatively inexpensive and the supply chain is relatively short. The growing demand proves that Schwöbel's business idea works. Cyclists and cyclists with seating problems are loyal customers. In the future, the company wants to become even more sporty and the saddles should be even lighter.
Beware of online bargains
The core business of Everve is the enjoyment of cycling through better seating. The small company from Albstadt is known in the scene as a trouser manufacturer with its own production facilities. The company is increasingly approaching this topic from the saddle position. The Wolfer brothers and founders see great potential in this. Stephan Wolfer, also an engineer, believes that the secret of comfort lies not in the padding, but rather in the saddle shell and frame. With Everve, these work like a "leaf spring" and absorb shocks that are transmitted to the body via the saddle when pedalling or due to bumps in the road. Paired with a customised saddle shape, which should offer the largest possible contact surface, "semi-customised saddles" are the best option in line with the company's philosophy.
To summarise: although the range of 3D saddles has increased significantly, a growing selection of models and increasing quantities have not yet led to any noticeable price reductions. On the positive side, manufacturers such as Fingerprint Cycling or Everce are showing that customised products with domestic production do not have to be more expensive than the 3D series models such as those from Specialized or Fizik as saddle suppliers to Evenepol and Pogacar, who have their sponsorship remunerated with price mark-ups at the shop counter. Ultimately, everyone has to decide for themselves what price good seating comfort is worth, as the range is constantly increasing. Caution is advised with bait offers such as 3D saddles from brands like Ryet for 50 euros. Apart from the lack of product information, there are justified doubts about product safety.
There are three printing processes
Fingerprint Cycling and Everve print in a layering process. Different materials are built up layer by layer. Fingerprint even produces the saddle shell from carbon fibre-reinforced material (E2CF). After printing, the padding is not post-cured and can be covered to protect the surface, seal the pores against dirt and make the surface more slippery for better gliding properties. Fizik, Specialized and Selle Italia work in a completely different way: they use stereolithography (SLA). In this process, liquid photopolymer is hardened with pinpoint accuracy using a laser. The elastic saddle pad must then be post-cured for several hours under UV light and cleaned. Custom manufacturer Posedla, on the other hand, relies on multi-jet fusion, also known as the powder bed fusion process. Thermoplastic powders such as nylon or TPU are fused by heat, the finished saddle lies in a bed of powder that is vacuumed and brushed. No post-treatment is required and there is no material waste. This shows that different processes characterise the trend towards 3D saddles - from series production to customised solutions.
Interview with Stephan Wolfer from Everve
Everve was founded by the brothers Andreas and Stephan Wolfer. Their small company from Albstadt, which is well-known in the scene, specialises in trousers and saddles, always with the aim of making cycling fun. We spoke to Stephan Wolfer about the opportunities and potential of 3D saddles.
TOUR In your experience, what factors influence seating comfort on the bike?
Stephan Wolfer: Sitting is a dynamic matter determined by cyclical load changes on the left and right. Positioning on the saddle is crucial; if you sit in the sweet spot, everything is fine, outside of it it becomes difficult. Another factor is the position on the bike. Professionals, in comparison to recreational cyclists, have a centre of gravity that is moved forward when they are stretched out. This is one of the reasons why they have comparatively few seating problems compared to hobby riders, provided they put a lot of pressure on the pedals of course.
Under the product name Ezero, Everve offers trousers without padding, together with minimally padded saddles. Is the padding ultimately just a myth?
Partly, partly. The contact area between the buttocks and the saddle is comparatively small; we sit on an area of about two credit cards. The idea of creating comfort here with the thickest possible padding does not lead to the desired result. The opposite is often the case, as a lot of padding offers a high potential for pressure points and friction during dynamic pedalling.
If the cushioning element between the bum and saddle is not so important, what is?
For us, the system of saddle and trousers is crucial. The trousers have no padding and are "only" responsible for preventing friction. The saddle has user-friendly, minimalist padding. We consider the geometry and flexibility of the saddle shell to be far more important. If the saddle shell is designed like a leaf spring, we can dispense with padding to compensate for dynamic peaks. Using a hybrid geometry (not too round, not too flat cross-section) and different widths, we want to offer each person as large a seating surface as possible - in order to minimise the resulting pressure.
You are the only manufacturer to offer a seat pressure measuring system that can be used to determine the pressure distribution on your own racer. Can I have the perfectly fitting saddle printed based on this data?
In my view, the answer is no! Despite real data, there are still too many unknowns in the system. A printed saddle is a very good approximation on the way to sitting better on the racer, but it does not solve every seating problem. One keyword here, for example, is seat flesh. A physiological mystery that varies from person to person.
What ultimately distinguishes this unique saddle from the competition's 3D saddles with their mostly open-pored structure and relatively thick padding?
Our saddles are not "one-offs" - not yet! We are talking about a "semi-custom" saddle here. Someone with seating problems or the desire for improvement will get a very good user-friendly base from us, especially in the system with the padless trousers, and can then fine-tune it themselves using the modular principle. In addition, a printed saddle should always have a closed, minimally slippery saddle cover instead of an open-pored surface that generates a lot of friction and slows you down. That is our philosophy.
Matthias Borchers
Editor
