Design and development of a sandwich-structured bike saddle prototype through a single three-dimensional printing process

Purpose This paper aims to investigate methods for designing and producing a 3D-printed bike saddle through a single 3D printing process that eliminates the need for additional manual assembly of parts. The study describes and illustrates the design and explores printing criteria for each component of the bike saddle. Design/methodology/approach A practice-based methodology was employed in this study to demonstrate a novel form of knowledge through design practice. Inspired by the construction of spacer textiles, the padding layer of the saddle was designed with a zigzag structure to provide shock-absorbing support for cycling. The rails part was designed to provide extra strength to the prototype. Findings This study compared the physical strength of new and original shapes of rail designs using the finite element (FE) method. With minor modifications to the rail geometry, computational analyses predicted a 23% reduction in the maximum absolute stress and a 49% decrease in deformation. In addition to the finite element (FE) analysis, compression testing was conducted using a custom hip model. The prototype remained structurally intact after ten cycles under a 230 kg load. Furthermore, results from a cycling durability test conducted over a period exceeding one year demonstrated that the prototype maintained its integrity after 1,000 km of riding. Originality/value This research addresses a knowledge gap in the development of an assembly-free bike saddle produced via a single 3D printing process. By developing and evaluating this design, the study offers valuable insights into both design theory and practical applications for similar products. Moreover, the study highlights the recycling potential of 3D printing materials; the bike saddle, made from thermoplastic materials using a Fused Filament Fabrication (FDM™) printer, facilitates recycling at the end of its lifecycle.