Development of an Ergonomic Additively Manufactured Modular Saddle for Rehabilitation Cycling.

ABSTRACT: This work reports the design, fabrication, and validation of a modular ergonomic saddle for rehabilitation cycling, developed through a combined additive manufacturing approach. The saddle consists of a metallic support produced by Laser Powder Bed Fusion (LPBF) in AISI 316L stainless steel and a polymeric ergonomic covering fabricated via Selective Laser Sintering (SLS) using thermoplastic polyurethane (TPU). A preliminary material screening between TPU and polypropylene (PP) was conducted, with TPU selected for its superior elastic response, energy dissipation, and more favourable SLS processability, as confirmed by thermal analyses. A series of gyroid lattice configurations with varying cell sizes and wall thicknesses were designed and mechanically tested. Cyclic testing under both stre

SUBMITTER: Iglesias Calcedo A 

PROVIDER: S-EPMC12654643 | biostudies-literature | 2025 Nov

REPOSITORIES: biostudies-literature