Carbon says its Digital Light Synthesis (DLS) process has now produced more than 1 million bike saddles, across 11 partner brands and more than 60 saddle models. The company announced the figure on October 21, 2026.
The brand list includes Selle Italia, Specialized and fizik. DLS replaces foam cushioning with programmable lattice structures that Carbon says let brands tune cushioning, support and ventilation by zone across the saddle shell, rather than relying on a single foam density.
The clearest on-bike proof point: Tadej Pogačar rode a custom fizik Argo Adaptive saddle to win the 2026 Tour de France, after also winning in 2025 on a 3D printed saddle. Carbon says seven finishers of the 2025 Tour rode 3D printed saddles.
Selle Italia’s new Unica saddle, made by Carbon production partner Prototek, is described as the second fully customizable saddle on the Carbon platform. It starts from pressure-mapping data captured per rider, which shapes the saddle’s internal lattice, and is printed in Carbon’s EPU 46 elastomer.
Carbon CEO Phil DeSimone called the milestone evidence that “digital manufacturing moves beyond prototyping and becomes a trusted way to make products at meaningful scale.” He also said more than 1,000 metric tons of material have shipped since launch in Carbon’s EPU Pro elastomer family alone, one of several material lines Carbon sells for the DLS platform.
Carbon has not published saddle unit costs, production lead times, or a per-brand breakdown of the 1 million total. The company will show saddles and other consumer parts, including footwear and helmets, at its Formnext 2026 booth (Hall 12.1, Booth F109) next month.