Carbon Produces One Million 3D-Printed Cycling Saddles
The additive manufacturing firm hits a milestone for its digitally programmed lattice saddle designs.
Updated on Oct. 21, 2026 in Cycling
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Carbon has officially manufactured over one million cycling saddles through its additive manufacturing platform. The firm currently supports 11 global brands with more than 60 different models.
Why it matters
The milestone underscores the scaling capabilities of 3D-printing in high-performance sports equipment. By using lattice structures, manufacturers can offer precision cushioning that was previously difficult to achieve with traditional production methods.
Carbon has utilized over 1,000 metric tons of EPU Pro high-performance elastomers for production. This output is managed by a network of 40 partners operating across 11 different countries.
The players
Carbon
Carbon is an additive manufacturing company that specializes in Digital Light Synthesis technology for high-performance product development.
Tadej Pogačar
Tadej Pogačar is a prominent professional cyclist who has achieved multiple major tour victories and competes at the elite level of the sport.
The details
Production relies on Carbon Digital Light Synthesis technology, which allows brands to program specific lattice geometries for optimized support and comfort. This technology has been utilized by professional athletes, including Tadej Pogačar, who raced using a Carbon-produced saddle.
Timeline
Tadej Pogačar raced with a Carbon-produced saddle in 2026.
Carbon is scheduled to exhibit at Formnext 2026 in Frankfurt in November 2026.
Season Trajectory
The widespread integration of 3D-printed components marks a shift in how cycling teams approach equipment optimization for professional races. This trend forces traditional manufacturers to adopt additive methods to remain competitive against brands utilizing lattice-based performance tuning.
Professional-grade 3D-printed saddles are becoming increasingly available to recreational riders through the 11 brands partnered with Carbon. Riders can choose from over 60 distinct models that offer customized comfort levels through unique lattice architecture.
The takeaway
The move toward digitally programmed lattice structures allows for greater customization in cycling gear than traditional foam padding ever could. Riders should consider whether their specific performance needs, such as weight distribution or pressure relief, benefit from these precision-engineered support designs.
Further reading
Learn more about the latest innovations in high-performance equipment in the Cycling section.
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