Making Custom Saddles More Accessible: The Story Behind the Joyseat PLUS
Personalized cycling saddles have traditionally belonged to the premium segment. The Czech company Posedla, known for its custom 3D-printed saddles, decided to push innovation further and bring a more affordable option to a wider community of riders without compromising comfort, ergonomics, or performance.
In collaboration with the Brain4Industry consortium, the Joyseat PLUS model was developer. New personalized and more affordable saddle that expands the world of custom saddles.
The original saddles used a carbon base and rails combined with custom 3D-printed padding , achieving excellent performance but also requiring a demanding manufacturing process. The Joyseat PLUS development therefore focused on creating a solution that reduces technological complexity and cost without compromising comfort or performance. The new structure uses a nylon base and stainless steel rails, while maintaining customization and enabling efficient serial production.
Topology optimization played a key role in the development, determining the optimal distribution of material within the saddle structure. Digital simulations and load analyses allowed the team to evaluate stress conditions and optimize the geometry for maximum stiffness with minimal weight. Rapid prototyping using SLS technology subsequently allowed multiple variants to be tested within a few months.
The result is a structure prepared for serial production that combines low weight, high strength, and rider-specific ergonomics. Joyseat PLUS provides a more accessible entry into the world of custom saddles while demonstrating that advanced engineering and innovative manufacturing technologies can deliver innovations with real market impact. The product is now available to customers and successfully expands the Posedla product portfolio.
At the same time, the project demonstrates how the combination of research, engineering development, and rapid prototyping can significantly accelerate the journey from concept to a market-ready product.
