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Hyperganic, Fizic, BASF Forward AM, atum3D, Dutch 3D Printer manufacturer, InnovationLab cooperated to create innovative mass-customized bicycle saddle

By Hyperganic

Machine: DLP Station 5-365 EXZ Industry: Automotive & Mobility Industry: Commercial Technology: Digital Light Processing Material: Ultracur3D® EL 150
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Hyperganic, Fizic, BASF Forward AM, atum3D, Dutch 3D Printer manufacturer, InnovationLab cooperated to create innovative mass-customized bicycle saddle

Redefining Comfort, One Layer at a Time: 3D Printed Bicycle Saddles - Innovating Ride Quality.



                        

Description

Innovative advancements in the cycling industry are revolutionizing performance and comfort. With the help of additive manufacturing solutions, companies can now create customized saddles tailored to the specific needs of each cyclist. Hyperganic worked with its partners Fizik, the Italian bicycle saddle brand, BASF Forward AM, the German material manufacturer, atum3D, the Dutch 3D Printer manufacturer, and InnovationLab, the German printed and organic electronics expert, to make the vision of going from 3D body scans to bike-ready saddles a fully-automated reality. To seamlessly transition from pressure maps to personalized saddle designs, the team at Hyperganic developed a purpose-built app on top of the existing Hyperganic Core platform. Hyperganic Core offers a suite of algorithmic engineering blocks that automatically design the thousands of struts that make up a saddle's lattice structure. In this case, the surface contours and lattice beam thicknesses are automatically adjusted based on the input pressure maps. The material used in the next-generation saddle is BASF Forward AM's reactive urethane photopolymer, Ultracur3D® EL 150. Consequently, this material is an excellent fit for the saddle due to its unique lattice designs that achieve the perfect balance between stiffness and compliance for use on any terrain. Therefore, the partnership with atum3D and the use of its DLP Station 5-365 EXZ printer for mass customization and waste minimization made a great contribution to bicycle saddle creation. The printer's capability to adjust print settings and its large build envelope enabled new levels of waste minimization and cost-effectiveness, especially for industrial-scale manufacturing.

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