German start-up Personomic, a spin-off from the University of Stuttgart, combines artificial intelligence and 3D printing to create custom-made bicycle saddles. The company designs its products to improve rider comfort while reducing environmental impact through local, circular production.

Personalised Design through AI and 3D Printing

The design process begins with an AI fitting tool that analyses a rider’s body data and cycling style. Using four anatomical parameters, the software creates a saddle shape that evenly distributes pressure and reduces strain on sensitive areas.

Personomic then produces each saddle using additive manufacturing technologies such as fused deposition modelling (FDM), selective laser sintering (SLS), and digital light processing (DLP). These techniques allow the creation of lightweight lattice structures that absorb vibration and increase comfort.

Sustainable and Regional Production

All saddles are made in Stuttgart from recyclable materials. The adhesive-free design makes it easy to separate and recycle every component at the end of its life.

The production facility runs on 100% renewable energy from wind and hydropower, supplied by the local utility company. Because all materials and components are sourced within Europe, transport distances remain short, which helps to lower carbon emissions.

In addition, Personomic reprocesses unused and returned materials in a closed-loop production system, reducing waste and conserving resources.

Research-Based Ergonomics

To ensure ergonomic precision, Personomic collaborates with the Institute for Engineering Design and Technical Design (IKTD) at the University of Stuttgart, Velometrik, and Eichinger Physiotherapy. These partnerships combine academic research, biomechanics, and medical knowledge. Together, they help develop saddles that support healthy posture and long-term performance.

Applications for Product and Mobility Design

Personomic’s process shows how AI, 3D printing, and circular design can come together in the development of personalised consumer products.

For product and mobility designers, the project highlights how local digital manufacturing can unite comfort, functionality, and sustainability in a single design solution. As digital fabrication grows, such approaches may influence the broader field of ergonomic and material innovation.

Source & photos: Personomic.bike