The AERIS bike saddle by Mahdi Naïm is developed through a combined approach of additive manufacturing and traditional craftsmanship. The structure uses high-precision photopolymerization, including SLA and DLP processes, to create a lattice from elastomer resin. This lattice varies in density across three zones, offering firm support at the rear, a transitional midsection, and an open perineal relief area to reduce pressure. The design removes traditional foam padding, relying entirely on the printed structure for performance and comfort.
The saddle is finished with hand-stitched leather applied over the printed base, produced in France to integrate material craft with engineered geometry. The stitching and surface treatment add durability and tactile contrast while preserving the underlying lattice performance. The project is designed as a unified system rather than layering separate techniques.
Image Credit: Mahdi Naim
Key Themes Behind This Trend
- Additive Manufacturing for Wearables
- Demonstrates how high-precision photopolymer lattices can replace foam padding in wearables to deliver tailored comfort through spatially varying density.
- Hybrid Craft-tech Products
- Combines artisanal hand-stitched leather with engineered printed cores to create objects that blend tactile heritage with measurable performance.
- Zoned Lattice Cushioning
- Shows how multi-zone lattice geometries provide targeted support and perineal relief while eliminating separate padding layers.
Where This Applies
- Cycling Components
- Customization of saddle geometry via additive manufacturing enables lighter, pressure-mapping-optimized bicycle components tailored to rider ergonomics.
- Orthopedic Seating and Prosthetics
- Pressure-relieving, patient-specific lattice structures offer new possibilities for personalized load distribution in medical seating and prosthetic interfaces.
- Luxury Leather Goods
- Integration of printed performance cores beneath hand-finished leather presents differentiation through enhanced durability, fit, and tactile contrast in premium accessories.
