3D printing is gaining momentum in the sports equipment sector, particularly in cycling. The Dutch brand PRO unveiled its first saddle featuring 3D-printed components: the Stealth 3D. This model uses additive manufacturing to improve rider comfort, optimize pressure distribution, and reduce the overall weight of the saddle.
Stealth 3D: Fabricated with 3D Printing
The Stealth 3D incorporates three distinct 3D-printed mesh zones, each with a different density. This approach allows the saddle’s support to be precisely adapted to the cyclist’s different positions, whether they adopt an aerodynamic or more upright posture.
While the exact 3D printing process has not been disclosed, PRO confirms that additive manufacturing makes it possible to:
- create complex geometries that are impossible to achieve with traditional foams,
- optimize the amount of material used,
- and reduce the overall weight of the saddle without compromising comfort.
Comfort, A Key Factor in Cycling Performance
In cycling, saddle comfort plays an essential role in overall performance. Poor seating can cause pain in the sit bones, pressure points, or loss of efficiency over long distances.
To design the Stealth 3D, the PRO teams drew on:
- pressure mapping data,
- postural studies,
- and feedback from users and testers.
These analyses made it possible to precisely identify the areas requiring more or less support depending on the cyclist’s position.
Three Density Zones to Adapt to Every Position
The Stealth 3D saddle is structured into three functional zones:
- Front zone (high density): designed to provide enhanced support for the sit bones when the cyclist adopts an aerodynamic position, leaning forward.
- Central zone (medium density): ensures even weight distribution in a more upright position, limiting pressure points.
- Rear zone (low density): helps reduce the overall weight of the saddle while maintaining sufficient comfort.
This gradual variation in density is only possible thanks to 3D printing, which allows precise control of the internal structure of the mesh.
The seat is designed in three zones.
3D Printing Allows for Advanced Design
Anton Peeters, PRO’s saddle design project lead, explains:
“The PRO Stealth 3D Saddle incorporates advanced manufacturing techniques with extensive research and development into rider comfort. The 3D printing process allows us to fine-tune the density in a way that is not possible when using conventional lightweight EV or PU padding.”
This ability to place material only where it is needed is one of the main advantages of additive manufacturing in sports equipment.
Technical Characteristics of the Stealth 3D Seat
According to PRO, the Stealth 3D is the most comfortable saddle ever developed by the brand. It is available with the following specifications:
- Available widths: 142 mm and 152 mm
- Weight: 224 g for the Team version; 260 g for the Performance version
- Lightweight, rigid carbon-reinforced shell
- Padding: 3D-printed EPU.
So, additive manufacturing is establishing itself as a key technology in the evolution of high-end cycling components. If you would like to find out more about this bike saddle, visit the PRO website HERE.
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*All Photo Credtis: PRO