3D-Printed Bicycle Saddle Lattice for Softness and Support
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Solution Overview
Problem
Existing 3D-printed bicycle saddles constructed with uniform lattice parameters lack both softness and sufficient support, failing to provide a comfortable and effective cushioning under sudden downward forces.
Innovation Solution
A 3D-printed bicycle saddle with an elastic pad featuring lattice struts that vary in diameter in a gradient manner, with varying lattice densities across different sections, ensuring a smooth transition from softness to support, enhancing comfort and supporting capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a lattice structure is constructed layer by layer with uniform lattice parameters, then the manufacturing process is simple, but the saddle cannot provide both softness and sufficient support
Solution Approach 1:
The lattice structure employs varying lattice parameters (different strut diameters, cell sizes, or densities) in different regions of the saddle. The top layer uses larger lattice parameters for softness, while deeper layers use smaller parameters for support, allowing each region to have optimized properties for its specific function.
Solution Approach 2:
The invention changes the lattice parameters (such as strut diameter, cell size, or density) as a function of depth or position within the lattice structure. This gradient variation in parameters enables the transition from soft upper layers to supportive lower layers within a single manufactured structure.
2Strength
If the lattice structure provides sufficient support for compression forces, then the supporting capability is improved, but the softness and elastic feel are reduced
Solution Approach 1:
The lattice structure is divided into multiple layers or zones with different lattice parameters. Upper layers have larger cell sizes or thinner struts for softness, while lower layers have smaller cell sizes or thicker struts for compression support, with intermediate layers providing a gradient transition between these extremes.
Solution Approach 2:
The invention introduces vertical dimensionality to the lattice parameter variation, creating a depth-dependent gradient where parameters change from top to bottom. This allows the structure to exhibit different mechanical properties at different depths, achieving both softness at the surface and support at the base.
3Ease of operation
If the lattice struts have varying diameters to provide gradient transition, then comfort is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The invention implements a controlled gradient variation of lattice parameters, where the change in strut diameter or cell size follows a predetermined pattern or function. This systematic approach allows the 3D printing process to accurately reproduce the gradient while maintaining manufacturing feasibility through programmable parameter evolution.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The saddle provides both soft haptics and high elasticity, improving comfort and support by distributing weight effectively and absorbing vibrations, while reducing material usage and maintaining a lightweight design.
Implementation Method 1
the elastic pad has a 3D-printed lattice structure comprising multiple lattice struts... the diameter of each lattice strut increases gradually in a gradient manner from the top surface to the bottom surface... the elastic pad features both soft haptics and high elasticity
Implementation Method 2
the elastic pad features both soft haptics and high elasticity in the vertical direction, thereby enhancing the comfort and supporting capabilities of the 3D-printed bicycle saddle
Data Source
Figure 1
Figure 2
Figure 3A
AI summary
The present disclosure provides a 3D-printed bicycle saddle (100) including a shell (110) and an elastic pad (120) disposed on the shell (110), wherein the elastic pad (120) has a bottom surface (120b) facing the shell (110) and a top surface (120t) facing away from the bottom surface (120b). The elastic pad (120) features a 3D-printed lattice structure including a plurality of lattice struts (140), wherein the diameter of each lattice strut (140) gradually increases in a gradient manner from the top surface (120t) to the bottom surface (120b) of the elastic pad (120). The difference between the maximum diameter and the minimum diameter of each of the lattice struts (140) is smaller than or equal to 0.5 mm.