Trek launches AirLoom 3D printed saddles

Trek, one of the best-known bicycle brands, embraced 3D printed saddles, like other top brands have done. On the one hand, this suggests that 3D printed saddles are likely to become the standard; on the other hand, Trek’s large volumes and reach already indicate that saddle 3D printing (mainly using Carbon technology) is scaling up significantly. The result is Trek’s AirLoom 3D printed saddles, a product that blends cutting-edge materials with biomechanical science. With AirLoom’s patent-pending lattice structure, Trek promises to deliver comfort, performance, and durability in ways that foam saddles can’t match.

Unlike traditional designs that rely on a dense foam wrapped in a rigid cover, AirLoom saddles feature an open lattice structure, carefully engineered to provide support where it’s most needed while flexing under pressure points. The result is simple: no pain, all gain.

Next-dimension comfort with AirLoom Lattice

AirLoom technology takes the saddle into a new dimension. By using 3D printed support zones, Trek created a seat that cushions sit bones while flexing beneath soft tissue. Riders no longer have to compromise between stiffness and comfort. Instead, they enjoy a balanced ride experience tailored to their natural movement.

Foam saddles often compress unevenly, leading to pressure build-up and sore spots. AirLoom avoids this problem by using open lattice cells that compress independently, ensuring each part of the rider’s body gets exactly the support it needs. This careful tuning means the saddle moves with the rider instead of forcing awkward adjustments.

Riders no longer slide across the surface to find relief. Instead, the saddle adapts naturally, eliminating friction and minimizing discomfort, whether on short training rides or long endurance efforts.

Comfort without compromise

Traditional foam saddles can feel like sinking into a mattress—comfortable at first but uneven over time. AirLoom sidesteps that issue entirely. With its lattice matrix, pressure distributes evenly across the saddle, offering all-day comfort without the drawbacks of foam compression.

AirLoom also strikes a balance between strength and weight, allowing riders to “ride on air” without sacrificing durability. Trek’s engineers trimmed material from the design without sacrificing support, creating one of the lightest lattice saddles available.

Trek introduced the AirLoom technology through its Aeolus line of saddles, ensuring options for racers, enthusiasts, and everyday riders alike.

• The Aeolus RSL AirLoom Saddle is built for performance at just 164 grams, pairing a carbon shell with lattice technology for the lightest, most responsive ride.
• The Aeolus Pro AirLoom Saddle blends professional-level features with balanced pricing, weighing 180 grams thanks to its carbon-nylon composite shell.
• The Aeolus Elite AirLoom Saddle delivers comfort and durability at an accessible price point, using a slightly thicker lattice and Austenite rails for value and reliability.

How Trek engineered the ultimate saddle

The AirLoom project began as a solution for Trek’s pro riders. Engineers were designing custom 3D-printed saddles for athletes, balancing stiffness and softness to alleviate pain during long races. After repeated successes, the team realized they could make a universal product that delivered the same benefits for all riders.

Led by design engineer Kayla O’Neill, Trek developed a patent-pending truncated octahedron lattice cell, chosen for its strength-to-weight ratio and progressive compression. This design ensures that even under heavy load, the saddle maintains a smooth, supportive feel instead of collapsing.

O’Neill describes the testing process as a search for the perfect “spring constant,” much like tuning a mountain bike suspension. After evaluating dozens of cell types in the lab, the truncated octahedron emerged as the winner.

Tested by the best, available to everyone

Before reaching the public, AirLoom was tested under the most demanding conditions—by Trek’s WorldTour riders and mountain bike racers. Athletes who spend 900–1,000 hours per year on the bike can’t afford saddle-related pain. The feedback was unanimous: AirLoom worked.

Gravel racer Haley Hunter Smith praised its ability to eliminate sit bone pressure and soft tissue pain, highlighting how the saddle allowed her to ride longer and train harder without discomfort.

What started as a pro-only innovation is now accessible to all riders. Trek transformed athlete-specific engineering into a product that every cyclist can enjoy, whether they’re chasing podiums or pedaling for fitness.