Shimano, a Japanese manufacturer of bicycle components and drivetrain systems, has introduced the Pro Stealth 3D Saddle, a new addition to its Pro Stealth range that incorporates 3D printed padding to manage rider pressure across different riding positions. The saddle uses a multi-density mesh structure developed from pressure-mapping data collected during bike fitments, combined with feedback from test riders, with the aim of improving comfort while maintaining the aerodynamic posture associated with the Stealth line.
According to the company’s launch information, the Pro Stealth 3D Saddle features three distinct mesh zones with different material densities. A high-density section is positioned at the front of the saddle to support riders as they tilt forward into an aggressive riding position. A lower-density middle section is intended to distribute rider weight across a wider surface area when sitting more upright, reducing concentrated pressure points. A low-density rear section reduces overall saddle weight because riders typically make limited contact with the rear portion of the saddle while pedaling.
Development of the saddle relied on pressure-mapping data gathered during professional bike fitting sessions, combined with feedback from test riders. Shimano states that this data informed both the placement of the mesh zones and their relative densities. This approach was used to retain the short-nose geometry and forward riding position characteristic of the Pro Stealth range while introducing a surface structure that adapts to changes in rider posture compared with conventional foam padding.
Beyond density zoning, the saddle incorporates a hexagonal cell geometry throughout its 3D printed padding. Shimano explains that this structure allows individual cells to deform under load, absorbing vibrations both individually and collectively. This behavior is intended to reduce road-induced vibrations transmitted to the rider, which can contribute to fatigue over extended distances. The hexagonal cells are left uncovered, which the company describes as a way to showcase the precision of the 3D printing process and visually expose the additive manufacturing structure used in the saddle’s construction.
This 3D printed padding is produced from expanded polyurethane (EPU) and includes a dimpled surface texture. Shimano states that the surface treatment is intended to help stabilize rider positioning on the saddle during seated efforts. Two construction levels are available. The Team version uses carbon rails, while the Performance version is equipped with INOX stainless steel rails. Both variants are offered in 142 mm and 152 mm widths, with claimed weights starting at 224 grams for the Team model and 260 grams for the Performance model, depending on configuration. In the UK, Shimano products are distributed by Madison, with pricing yet to be confirmed at the time of publication.
3D printed saddle design gains traction across performance cycling
The growing use of 3D printing in bicycle saddle design has been evident in recent product launches focused on pressure distribution and adaptive support. Trek introduced its AirLoom saddle platform, which uses a 3D printed lattice structure to address uneven pressure, friction, and hotspots across different riding disciplines. Unlike traditional foam saddles, the AirLoom design relies on an open lattice that allows individual cells to move independently, cushioning sit bones while flexing under softer tissue. Trek positioned the approach as a way to reduce saddle sores and improve long-ride comfort by allowing the saddle surface to adapt dynamically as the rider shifts position. The AirLoom range spans multiple configurations, from the 164-gram Aeolus RSL AirLoom with a full carbon shell and rails to more accessible versions that use thicker lattices and alternative rail materials.
A similar design philosophy was highlighted with the release of the Scratch M5 PAS 3DMSS saddle from Prologo, which applied 3D printing to the saddle’s upper surface while retaining an existing geometry used by professional riders. The Italian manufacturer combined its Multi Sector System with digital light projection and engineering-grade resins to create a surface divided into front, center, and rear zones, each with distinct structural densities. Development was informed by pressure-mapping data collected through Prologo’s MyOwn fitting system, drawing input from both professional and amateur cyclists. The design retained a central pressure-relief channel and was offered with multiple rail options, reflecting an emphasis on localized material tuning rather than changes to saddle shape.
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Featured photo shows Close-up of Shimano’s new Pro Stealth 3D Saddle. Photo via Shimano.
