Carbon + Specialized - Reimagining the Bike Saddle Through 3D Lattice Innovation

A Case Study in Digital Manufacturing, Rapid Iteration, and Breakthrough Rider Performance

Specialized is one of the world’s most respected performance cycling brands — a company built on relentless innovation and a deep understanding of the rider experience. When they set out to reinvent the bike saddle, they knew traditional materials like foam and gel had reached their limits. To create the next breakthrough in comfort and performance, they needed a partner capable of pushing beyond the constraints of conventional manufacturing.

Carbon became that partner.

Together, Carbon and Specialized created the S‑Works Power Saddle with Mirror Technology — the world’s first 3D‑printed lattice bike saddle, crafted using Carbon’s Digital Light Synthesis™ (DLS™) platform. The result is a product that redefines comfort, accelerates performance, and sets a new benchmark for the future of cycling equipment.

The Challenge

A 150-year-old component overdue for reinvention

Despite decades of innovation in cycling, the saddle — one of only three points of contact between rider and bike — had barely evolved. Foam‑based saddles had been pushed to their engineering limits, and Specialized needed a way to:

  • Deliver better pressure distribution

  • Improve comfort for long‑distance riders

  • Increase performance through optimized support

  • Move beyond the constraints of foam and gel

  • Bring a radically new product to market faster than ever

Traditional manufacturing couldn’t get them there.

The Opportunity

A digital manufacturing platform built for breakthroughs

Carbon’s platform offered Specialized something no other process could:

  • Multi‑zone lattice design with 14,000+ individually tunable struts

  • Precise control over mechanical response and rider‑specific pressure zones

  • Rapid iteration — from print to ride testing in days, not months

  • Scalable production from low‑volume prototyping to high‑volume manufacturing

  • A single elastomer material optimized for comfort, support, and durability

This wasn’t just a new saddle. It was a new way to design and manufacture performance cycling equipment.

Our Approach

A two‑video campaign: a technical case study + a rallying brand film

Watts Media partnered with Carbon to produce two complementary pieces:

1. The Explainer / Case Study Film (2 minutes)

A narrative‑driven, engineering‑forward story that shows:

  • Why Specialized needed to rethink saddle manufacturing

  • How Carbon’s platform enabled a 3D‑printed lattice impossible with foam

  • The development process — from first print to human testing in 3 days

  • The 70+ design iterations that shaped the final product

  • The impact on rider comfort, pressure relief, and performance

  • What this partnership means for the future of cycling innovation

The film blends:

  • On‑camera interviews

  • High‑resolution product cinematography

  • Technical motion graphics

  • Lattice visualizations

  • Real rider testing moments

The tone is premium, precise, and deeply aligned with both brands.

2. The Rally Video (30 seconds)

A fast, inspirational anthem designed for social channels — LinkedIn, YouTube, Twitter, Facebook — highlighting Carbon as the digital manufacturing platform that enables:

  • Faster innovation

  • Breakthrough product design

  • Seamless scaling from prototype to production

  • The ability to “make the impossible”

This piece drives awareness and funnels viewers to the full case study.

The Development Story

From 24 months to 10 months — a new pace of innovation

At the heart of the story:

  • First saddle printed in one day

  • Human testing began three days later

  • 70+ design iterations completed in record time

  • Development cycle cut from 24 months to 10 months

  • Pressure mapping and comfort testing guided every iteration

  • XMR light engine used for the first time in a commercial 3D‑printed application

This speed and precision are unheard of in traditional saddle development.

The Product

The S‑Works Power Saddle with Mirror Technology

The final saddle features:

  • A 14,000‑strut lattice tuned for rider‑specific pressure zones

  • A single‑piece elastomer structure grown with light and oxygen

  • A surface topology engineered for both grip and glide

  • A design that reduces peak pressure by up to 28% compared to foam

  • A breathable, open‑cell structure for long‑ride comfort

  • A sleek, modern aesthetic that signals next‑generation performance

Riders immediately feel the difference — comfort, stability, and power transfer all improve.

The Impact

A breakthrough for Specialized, Carbon, and the future of cycling

For Specialized:

  • A category‑defining product

  • Faster time‑to‑market

  • Greater control over performance characteristics

  • A new design language for future components

For Carbon:

  • A flagship example of the Carbon Digital Platform in action

  • Proof of scalable, high‑performance lattice manufacturing

  • A hero story for business development and GTM campaigns

For riders:

  • Better comfort

  • Better pressure distribution

  • Better performance

  • A saddle that feels custom‑tuned to the human body

As Specialized says: “Saddles are just the start.”

This partnership opens the door to reimagining every touchpoint between rider and bike.