3D printing company Carbon says more than a million bicycle saddles have now been produced using its additive manufacturing system.
Cycling brands use its Digital Light Synthesis (DLS) process to print lattice structures with cushioning and support that can be adjusted across various parts of a saddle.
The company works with 11 saddle brands worldwide, with more than 60 models in production.
“Reaching one million saddles is an important milestone, but it represents much more than a production number,” said Phil DeSimone, CEO of Carbon. “It shows what happens when digital manufacturing moves beyond prototyping and becomes a trusted way to make products at meaningful scale. Together with saddle brands and production partners, we have created an entirely new category of cycling products – moving from the first applications of lattice technology to products being ridden every day by consumers and by athletes competing at the very highest level of the sport.”
The printed lattices replace conventional foam cushioning and can be tailored to a rider’s pressure profile and riding position. At the 2026 Tour de France, Tadej Pogačar again raced on a custom fizik Argo Adaptive saddle made using Carbon DLS and fitted through fizik’s One-to-One programme.
Selle Italia has also launched a personalised saddle, Unica, produced by Carbon partner Prototek. It uses pressure-mapping data from the cyclist to design an internal lattice around their pressure distribution, printed in Carbon’s EPU 46 material. Unica is the second fully customisable saddle made using the Carbon system.
Carbon’s technology is also used to make personalised footwear. Vivobarefoot’s VivoBiome Tabi Gen 02 uses individual foot scans and Carbon DLS to produce made-to-order shoes.
Together, these applications reflect how Carbon is helping brands move complex product concepts into repeatable commercial production, while making customization practical at production scale.
The company works with more than 40 production partners worldwide. These give brands access to Carbon manufacturing closer to their markets, supporting the move from development to commercial production and providing extra capacity as production increases.