High-Performance Bicycle Saddle in Hybrid Design

The individualization of the Hypersaddle enables a high level of comfort as well as lightweight design.

The bicycle component with probably the most influence on comfort is the saddle. A large part of the body weight bears on the very sensitive sitting area of the human body. This can lead to various complaints, such as numbness, sitting pain and general discomfort. The remedy is a saddle shape tailored to the individual anatomy, which distributes the pressure to less sensitive sitting areas. To achieve individualization, a pressure distribution is determined in a bike fitting process by taking into account body posture, seat position and saddle adjustment. In a digital process chain, the saddle model is individualized based on the pressure distribution. An economical production of this individual piece requires flexible process technology. Such flexibility is achieved by combining the classic prepreg autoclave process with modern 3D printing technology. In this process, a near-net-shape preform of the saddle shape is produced from tapes (carbon fiber bundles impregnated with epoxy resin) in a robot-assisted laying process. The preform achieves its individual saddle shape in the autoclave process using a mold with individualized 3D printed inserts. The Hypersaddle is completed by a lightweight optimized saddle rail combining unidirectional prepreg tapes, a carbon fiber braided tubing and a foam core. With the 5th design variant, a saddle design was developed after continuous optimization which is supposed to set new standards regarding the combination of ergonomics and lightweight design.



Tim Schmidt

Scientific Staff Digitalized Process & Material Development

Telephone: +49 631 2017 469


Dipl.-Ing. (FH)

Thomas Pfaff

Laboratory Engineer Design of Composite Structures

Telephone: +49 631 2017 116



The project “Hypersaddle – Personalised High-Performance Bicycle Saddle in Hybrid Design“ is funded by the central innovation program (ZIM) of the Federal Ministry for Economic Affairs and Climate Action on the basis of a decision by the German Bundestag (funding reference ZF4052331RF9).