Variable Density Lattice Bike Saddle

Tools & Technologies

Project Overview

Inspired by the high-end additive manufacturing used in the cycling industry, I set out to design and build a custom 3D-printed lattice bike saddle to rival the expensive options on the market. This project was a deep dive into complex surfacing; I used the Phi3D Onshape add-on to sculpt the organic geometry of the saddle skin, iterating through multiple profiles to dial in the ergonomics. For the functional core, I leveraged the Carbon Design Engine to generate a variable-density Voronoi lattice using EPU41, a resin selected specifically for its foam-like elasticity and durability.

To ensure the design was functional and not just aesthetic, I conducted FEA simulations to validate the structure, refining the geometry to reduce deflection and achieve a safety factor of 5 at critical stress points. I also engineered a rigid support pad printed in ASA—chosen for its UV stability and thermal resistance—to interface between the flexible lattice and the bike hardware. This required designing a custom two-part clamping assembly that utilized heat-set inserts to securely grip the carbon saddle rails.

The fabrication phase ended up being a high-stakes test of my design work. Due to the limited availability of the specific printer required for the lattice, I only had the ability to print once. I had to carefully navigate challenges with resin drainage and the fragility of the "green state" parts during support removal to ensure that the print survived post-processing. Fortunately, the engineering held up: despite being a prototype, the saddle proved incredibly durable, and I still use it on my bike over a year later.