Carbon Produces One Million 3D-Printed Cycling Saddles
The milestone underscores the growing scale of lattice-based support for cyclists seeking custom pressure relief.
Updated on Oct. 21, 2026 in Cycling
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Carbon has officially surpassed one million 3D-printed cycling saddles produced through its global additive manufacturing network. The milestone highlights the expanding scale of digitally programmed, lattice-based cushioning technology in high-performance cycling gear.
Why it matters
As 3D-printed lattice structures become common in professional cycling, they offer riders highly customizable support and cushioning profiles. This manufacturing milestone confirms that additive technology has moved from niche innovation to a mainstream production process for global cycling brands.
Carbon reports over one million units produced across 60 distinct saddle models, supported by 1,000 metric tons of high-performance elastomer shipped since launch. The long-term physical degradation rates of these specific lattice structures compared to traditional foam remains under investigation.
The players
Carbon
An additive manufacturing company that provides Digital Light Synthesis technology for high-performance sporting equipment.
Tadej Pogačar
A professional road racing cyclist who has used 3D-printed saddle technology during competition.
The details
The technology relies on Carbon Digital Light Synthesis, which uses light and oxygen to cure liquid resins into complex, digitally programmed lattice geometries. By adjusting the density of these lattices, manufacturers can precisely tune the cushioning and mechanical support in different zones of a single saddle. This process allows brands to create end-use products that optimize pressure distribution for athletes, such as Tadej Pogačar, who utilize these components in competition.
Timeline
2026: Tadej Pogačar raced using a Carbon-produced saddle.
November 2026: Carbon will exhibit at Formnext 2026 in Frankfurt.
Health Landscape
The widespread adoption of Carbon Digital Light Synthesis technology reflects a broader shift toward mass-customized equipment in endurance sports. This approach marks a departure from traditional closed-cell foam saddles by allowing for granular, zone-specific support that can be digitally tailored to rider biomechanics.
Cyclists interested in 3D-printed saddles should prioritize fit assessments, as these lattice structures offer different pressure relief patterns than traditional foam. Discuss whether a lattice-designed saddle is appropriate for your specific riding position or sit-bone anatomy with a qualified bike fitter.
The takeaway
The move toward 3D-printed components represents a significant shift in how cycling gear is engineered for comfort and pressure management. If you are experiencing discomfort or numbness during long rides, talk to a bike fitter about whether equipment with customizable lattice support may help.
Further reading
For more information on the latest gear technology, visit the Cycling section.
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