WE INTERVIEW ALEX LOCATELLI - Head of Brand Fizik

Today we interviewed Alex Locatelli, Head of Brand Fizik. Alex tells us about saddles featuring the One-to-One system, manufactured using 3D printing.

1.-Every cyclist rides and positions themselves on the saddle differently, but why is a custom saddle so important?:

Alex: Precisely because every cyclist sits and moves on the saddle differently, customisation can make a significant difference. Modern saddle technology has made enormous progress, offering different shapes, profiles and levels of support, as well as a range of padding solutions, from traditional EVA foam to advanced 3D-printed structures, an area in which fizik has been a pioneer.

Every cyclist is unique, not only in terms of anatomy, but also in riding position, pedalling dynamics and individual sensitivity. As the saddle is one of the main contact points between the rider and the bicycle, it plays a critical role in comfort, performance and the rider’s overall well-being. Selecting the correct saddle is therefore essential, and personalising its support characteristics can provide considerable benefits by addressing the rider’s individual pressure distribution rather than relying solely on a standard solution.

2.-Do you think 3D printing has revolutionised saddle design?:

Alex: Yes, definitely. 3D printing has transformed both the way saddles are designed and the way their performance can be engineered. The technology we use allows us to create padding with precisely differentiated support characteristics across different areas of the saddle, something that would be extremely difficult to achieve using conventional foam-manufacturing processes.

This technology also made our One-to-One customisation system possible. It enables us to convert an individual rider’s dynamic pressure map into a unique padding structure designed specifically around the way that rider interacts with the saddle.

Foto: Fizik

3.-What does a dynamic pressure-mapping session involve?:

Alex: To produce a custom saddle, we analyse the pressure pattern generated by the cyclist while riding their own bicycle in their normal riding position.

The first step is to identify the most appropriate saddle shape. We have developed an algorithm that recommends the optimal shape based on the data collected, although this selection can also be made manually by an experienced bike fitter.

Once the correct shape has been identified, we perform a second dynamic pressure-mapping session to analyse how the cyclist loads the saddle while pedalling. The resulting pressure data is transferred through a dedicated mobile application to our servers, where it is processed and translated into a unique production file. From this file, we generate and 3D-print the rider’s personalised padding.

The important point is that we are not working only from static anatomical measurements. We are observing the cyclist dynamically, on their bicycle, while they are actually pedalling.

4.-How do you create the different variable-density zones within each saddle?:

Alex: This is one of the key properties of the 3D-printing technology we use. By controlling the structure and mechanical behaviour of the printed padding in different areas, we can create zones that provide different levels of support and response within a single continuous structure.

The precise way in which the pressure data is translated into these differentiated zones is part of our proprietary One-to-One process, so we cannot disclose the full technical details.

5.-In competition, would you advise a rider to use different saddles depending on the type of race, for example, Paris - Roubaix compared with a mountain stage finishing on Alpe d’Huez?:

Alex: Potentially, yes. Our system makes it possible to refine the padding for a particular application, especially when the rider’s position or interaction with the saddle changes significantly between different types of racing.

For example, the demands of a race over rough cobblestones may be different from those of a mountain stage, where the rider may spend more time climbing and frequently changing position. However, this does not necessarily mean that every rider needs a different saddle for every race. A well-developed custom saddle should already provide a highly effective balance of support, comfort and stability across a wide range of conditions.

For riders with very specific requirements, particularly at the highest level of competition, it is nevertheless possible to analyse different scenarios and develop application-specific solutions.

Foto: Fizik

6.-What is it that really makes the difference with a 3D-printed saddle?:

Alex: A 3D-printed padding structure allows us to use a material and architecture with mechanical properties that are particularly well suited to the demands of a bicycle saddle.

The main advantage is the ability to precisely control how different areas of the padding behave. This allows us to manage the rider’s pressure distribution more effectively, improve weight support and provide greater stability without making the entire saddle uniformly softer.

The open structure of the padding also provides excellent ventilation. This can help reduce heat and moisture build-up, which in turn may limit the friction and discomfort that can develop during long rides.

Ultimately, the major difference is precision: rather than using one uniform piece of foam, we can engineer the response of the saddle area by area and, with One-to-One, adapt that response to the individual cyclist.

7.-How do you expect saddles to evolve in the future?:

Alex: We expect 3D printing to continue evolving through the development of new materials and increasingly sophisticated manufacturing processes. These advances should allow us to achieve even greater precision, reduce weight and maintain, or further improve, the durability and longevity of the product.

We also believe that data-driven personalisation will become increasingly important. The combination of dynamic rider analysis, advanced algorithms and additive manufacturing gives us the opportunity to move beyond the traditional concept of selecting a saddle from a range of standard options.

The future will not simply be about creating softer or lighter saddles. It will be about understanding more precisely how each cyclist interacts with the bicycle and producing a solution that is increasingly tailored to that individual rider.