OECHSLER and Forward AM

Put the Smiles back in the Miles

Motorbike saddle
Why Forward AM and OECHSLER
Covering the value chain from material development to global production
Material used
Ultrasint® TPU01
The Result
Reduced production complexity and superior seating experience

Whether it’s a bicycle or motorbike, the saddle is the paramount comfort factor of every two-wheeler. Bikers know that a comfortable saddle is vital – without it, any tour quickly becomes torture. Forward AM and OECHSLER developed a superior solution for bikers.

Leading German AM material specialist Forward AM and OECHSLER teamed up to develop a new-generation motorbike saddle by harnessing the advantages of AM. While OECHSLER market and product know-how was essential for the development and programming process of the seat, advanced material from Forward AM is key to enabling the functional benefits.

Using industrial-scale 3D printing technology and high-performance Ultrasint® TPU01, the two companies designed a motorbike saddle that delivers the comfort riders demand. The objective was to enhance the in-saddle experience by taking the biomechanical specifications of different customer groups into account, across all segments including sports bikes, tourers, and off-roaders.

Fewer assembly steps

Greater comfort

Thanks to the design freedom enabled by Additive Manufacturing, the saddle can be produced in a single piece – reducing assembly time and ultimately cost. Thanks to freely designable lattice structures only possible with Additive Manufacturing, a fully integrated cushioning experience unlocks greatly enhanced comfort.

The material of choice, Ultrasint® TPU01 by Forward AM, is ideal for the production of parts requiring excellent long-term shock absorption, energy return, and flexibility. Parts printed with Ultrasint® TPU 01 deliver strong, flexible and durable performance, combined with excellent surface quality and level of detail.

Inside product development

Material choice

Ultrasint® TPU01 opens unlimited design possibilities: it is extremely easy to print, has a very high process stability, and one of the highest throughputs for flexible materials in the 3D printing market. These unique characteristics make it a perfect fit for serial production with HP Multi Jet Fusion printers. With Ultrasint® TPU01, flexible lattice structures become easily possible.

The saddle consists of several layers of differing cushioning structures, combined in a single pad. The specific mapping of the cushioning surface was the result of extensive digital simulation and real-world testing.

"The motorcycle saddle is a core interface between rider and motorcycle. Additive Manufacturing enables us to go beyond the limits of conventional materials and manufacturing processes, and deliver greater comfort and safety." - Max Lehnert, Program Manager AM Lattice, OECHSLER.

The Results

The Patch PRO (3D) enables the rapid reinforcement or refining of soft 3D components. In summary, the machine delivers the following advantages:

  • The elimination of expensive tools allows for both short run and fast reaction projects
  • It can be used in prototyping or series production to achieve design, comfort, or stiffening requirements
  • The Patch PRO (3D) realizes a competitive alternative to high-priced engineering polymers while optimizing the topology
  • In design applications where manual double layering of patches has reached its limits the automation allows for precision placement.

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OECHSLER and Forward AM

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Let's talk about your ideas - we are ready to support your project. Markus Bischoff Business Development Management Innovative Solutions
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