Seven out of ten Tour de France finishers used Carbon 3D printed saddles

As Carbon founder Joseph DeSimone stated, likely, most of the 180 million bike saddles produced annually will eventually be made using 3D printing. The benefits in terms of comfort and performance are just too clear. The 2025 Tour de France reinforces this claim, with seven of the ten finishers sporting 3D printed saddles, including the winner, Tadej Pogačar, from UAE Team Emirates.

Pogačar and fizik, One to One

Pogačar’s saddle was tailor-made using Carbon DLS technology by fizik. The company’s One-to-One program provides personalized saddle design, integrating advanced biomechanical data and high-precision manufacturing techniques. This approach delivers one-of-a-kind custom saddles developed to match an individual rider’s anatomical and performance needs, replacing generalizations with specific, data-driven solutions.

The journey begins with a dynamic pressure-mapping session conducted at an authorized One-to-One dealer. Utilizing proprietary technology developed in collaboration with the biomechanics specialists at gebioMized, this session captures live pressure data as the rider pedals. The system records detailed information about pressure peaks, asymmetries, hotspots, and areas of instability. Unlike static fitting methods, this dynamic approach ensures that the measurements reflect the rider’s actual position and movement during cycling.

This pressure profile then serves as the foundation for creating a custom saddle. Fizik employs Carbon Digital Light Synthesis to fabricate the saddle’s padding. This process enables the precise tuning of support and relief zones, ensuring firmness where structural support is crucial and softness where pressure distribution is critical. The result is a saddle uniquely structured to accommodate each rider’s distinct pressure pattern, providing tailored functionality and improved comfort over long rides.

Once production is complete, the saddle is shipped directly to the designated address. The One-to-One program also includes the opportunity for a follow-up session with the original dealer. This second pressure-mapping test is used to compare data before and after the saddle fitting, highlighting improvements in pressure distribution, rider balance, and ergonomic alignment.

Data-driven, 3D printed saddle fit

The physical advantages of a customized saddle extend well beyond comfort. Targeted support reduces the risk of repetitive strain injuries and discomfort associated with long-term cycling. Many common issues—such as numbness, joint stress, or muscle fatigue—can be significantly mitigated by aligning saddle design with real biomechanical data. Enhanced comfort also translates into better efficiency; when the rider maintains a stable and natural position, less energy is spent compensating for poor fit or shifting posture.

In professional settings, the impact can be substantial. Athletes training for endurance events or competition require consistent support to maintain optimal performance. For amateur cyclists and recreational riders, a personalized saddle can mean the difference between occasional discomfort and long-lasting enjoyment of the sport. Commuters and long-distance cyclists, in particular, stand to benefit from the long-term ergonomic advantages provided by a custom-fit saddle.

Beyond its immediate application, the One-to-One program exemplifies a larger movement toward personalized cycling gear. The integration of motion-based data and adaptive manufacturing opens possibilities for future advancements in other equipment categories such as cycling shoes, grips, and protective gear. Fizik’s approach highlights how precision engineering and rider-specific insights can come together to push the boundaries of performance and comfort.

Getting one-to-one

To access the One-to-One program, riders must visit an authorized fizik dealer equipped with the required pressure-mapping tools and expertise. The process is highly technical and includes both initial assessment and follow-up analysis. Fizik has built a global network of partners to deliver consistent quality and professional experience throughout each stage of the program.

Retailers interested in becoming a One-to-One dealer can apply directly through Fizik. Participants receive specialized training, access to proprietary equipment, and ongoing support. Offering this level of customization enables retailers to meet the growing demand for personalized cycling solutions and position themselves as leaders in performance-oriented fitting services.

In summary, the fizik One-to-One program represents a major advancement in how cycling equipment is conceived and delivered. Fizik offers a product that is technologically sophisticated and deeply responsive to the needs of modern cyclists. It sets a new benchmark for what personalized performance can look like in the world of cycling.