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Text: James Woodcock
Carbon says more than one million cycling saddles have now been produced on its end-to-end additive manufacturing platform using Carbon Digital Light Synthesis (DLS). The company now partners with 11 saddle brands and has more than 60 saddle models in production. Its technology enables brands to replace traditionally manufactured foam cushioning with programmable lattice structures whose mechanical response can be tuned across different areas of the saddle.
One of the latest is Selle Italia’s Unica, produced by Carbon partner Prototek in Carbon’s EPU 46 material. Unica uses pressure-mapping data captured from the individual cyclist to engineer an internal lattice around that rider’s pressure distribution. Carbon says it is the second fully customizable saddle made with its platform. At the 2026 Tour de France, Tadej Pogačar raced on a custom fizik Argo Adaptive saddle produced with DLS and tailored through fizik’s One-to-One program to his pressure profile and riding position.
“It shows what happens when digital manufacturing moves beyond prototyping and becomes a trusted way to make products at meaningful scale,” said Phil DeSimone, CEO of Carbon. The company reports more than 40 production partners in 11 countries and says more than 1,000 metric tons of its EPU Pro elastomers have shipped since launch. Beyond cycling, Carbon cites Vivobarefoot’s VivoBiome Tabi Gen 02, which uses a scan-to-print model with DLS to turn individual foot-scan data into made-to-order footwear.
At Formnext, Carbon will be on booth F109 in Hall 12.1, showing customer applications already in production across cycling, custom footwear, protective equipment, mobility seating, medtech, industrial and automotive.
Carbon at Formnext 2026: Hall 12.1, Booth F109
Carbon at the Industry & Application Stage: From Scan to Print: How VivoBiome, Oechsler, and Carbon Built a Production-Scale Personalized Footwear Platform
