A 3D Printed Saddle Rode to the Finish Line at the Tour de France

Through the excitement and fanfare of the last stage of the Tour de France, one of the quiet stars of the competition didn’t even pedal at all. Beneath Slovenian cyclist and Tour de France Winner Tadej Pogačar, a sleek $400 3D printed saddle helped shape his triumph. The bike saddle itself was 3D printed using technology from the company Carbon Adaptive, and helped Pogačar during the last stage of the Tour de France in Paris.

The Italian cycling brand Fizik was behind the device called the Vento Argo 00 Adaptive, and it signals a growing trend where sports have intersected with additive manufacturing. Each saddle is tailored and customized to the rider using Carbon Adaptive’s One-to-One Program. The program uses Digital Light Synthesis (DLS) to 3D print a lattice structure unique to the athlete’s anatomy and riding style. For Pogačar and the UAE Team Emirates, that meant producing an ultra-lightweight and high-performance saddle that could handle one of the toughest global events for cycling.

The adaptive 3D printed lattice and full carbon frame deliver both comfort and speed. (Credit: Fiznik, Carbon Adaptive)

Unlike traditional saddles that are often made from foam and offer a uniform feel across the surface, the Vento Argo 00 Adaptive enables micro-tuned zones of stiffness and support for the rider. This helps better distribute pressure on inclines and reduce numbness for the rider on long distances. Due to its 3D printed nature, the geometry of the saddle can be customized at a level once unattainable for mass production. For Fizik, the move to additive manufacturing showcases a shift towards products specifically customized for cyclists. While the standard Vento Argo 00 Adaptive is available for consumers, the version used by Pogačar at the Tour de France was fully customized and fine-tuned to ensure every marginal gain possible for the competition.