Selecting the perfect cycling saddle can be a long and painful process trying and buying multiple saddles. Riding on the wrong type of saddle can cause various irritations and can even result in erectile dysfunction (Goldstein, 2007) and may in the end spoil the fun of cycling.

A direction in the design of female saddles was chosen because all of the female questionnaire respondents experienced discomfort while cycling (appendix 7). The project was done with saddle brand PRO, which doesn’t have a female saddle shape yet in their product portfolio and most saddles on the market are based on male research. Male cyclists have various male based saddle shapes to choose from, females only a few.

Female cyclists have a larger sit bone angle and a greater sit bone width. They also prefer a different pressure division on the saddle compared to male cyclists. Next to these anatomical differences, chaffing of the saddle nose, during the leg movement, is a problem that often occurs for females.

Increasing the lifespan of the saddle, being able to repair or upgrade the saddle and adjusting the comfort level are things respondents seek in a new saddle (appendix 6) and are in my opinion the best way to be more sustainable. With a modular saddle structure, the durable use of carbon fibre can be extended over a longer time frame and be standardized.

Additive manufacturing has the potential to be a manufacturing method for PRO saddles. Advantages are that forces can be locally absorbed by geometry and ductility can be modified. It is essential for PRO to get acquainted with the technique now to keep up with competitors. Next to that, this process allows customization and local production and could bring longevity by upgrades over the lifespan of the product. Being able to adjust the ductility and form is especially desirable for female cyclists, who have more sensitive pudendal nerves in their pelvises (Bicyclelab 2012).

The availability of new additive manufacturing methods and the clear focus of Shimano to produce saddles with low environmental impact, make room for this new approach. Therefore, the goal of this project is to design a solution that captures females’ requirements and transform these into a road/gravel saddle. Women should be able to select the right saddle within the PRO collection.

To determine sensitive focus areas, a sensitivity map (appendix 12) was made and is promising as a tool for future saddle design. This map adds in relieving sensitive zones and will increase the chance of designing a more comfortable saddle. This research showed that variation in female saddles is particularly needed in the current nose width, hardness and cutout position of the saddle.

Research shows (appendix 6) that users want to be able to adjust their saddle to achieve the highest personal comfort levels. This Modular Saddle System [MSS] could give users the possibility to adjust their saddle to their preferences. With a modular saddle structure, the durable use of carbon fibre could be extended over a longer time frame. Next to that, being able to repair or upgrade can increase the lifespan of their saddle.

To validate the concept of a modular saddle, models are made based on the most comfortable rewarded (appendix14) PRO saddle. A pressure map was used to prove or show what people feel when sitting on a saddle, together with a Likert comfort scale rating.

Having modular parts depending on parameters like weight and personal preferences will allow every rider to be able to find the correct saddle in the PRO product portfolio.