Combining 3D printing and knitting : a new approach to integrated saddle design

Abstract

The application of 3D printed knitted structures presents new opportunities for enhancing the performance and customization of sports equipment. By leveraging the unique properties of knitted spacer fabrics through advanced 3D printing techniques, it becomes possible to optimize both shock absorption and structural integrity. This approach was explored in the context of bicycle saddle design, where the integration of soft layers and rigid bases was achieved using a combination of finite element simulations and prototype development. The addition of continuous carbon fibres and onyx enabled precise control over rigidity and flexibility, facilitating the seamless production of saddles in a single 3D printing process. A comprehensive research methodology, including literature review and practice-based design, guided the evaluation of novel lattice structures and modified rail geometries. Physical testing with a custom hip model and finite element analysis demonstrated that minor adjustments to rail design could reduce maximum absolute stress by 23% and deformation by 49%. The prototype remained structurally sound after repeated loading and sustained its integrity over 1,000 km of cycling.