Portfolio Disclaimer
This website is a showcase of my design work and personal projects. Please note that I am not a company, freelancer, or sole trader. Although some projects may appear to be commercial, they are entirely my own creative endeavors. Any mention of copyright reflects my rights to protect my original work under applicable law. This site is not intended for selling products or representing any business; all content is presented solely for demonstration purposes.Â
Integrating Hydesign into novel 3d Modeling Workflows
An independent research on accelerating design iterations and improving ergonomic bike saddle padding feasibility
📅 Publication Date: 20.06.2024 | 🔄 Latest Review: 06.03.2025
#3dPrintedBikesaddle #HyDesign
Abstract
This project was conducted independently as a small part of my self-financed research aimed at addressing the challenges of prolonged seated pedaling, particularly in stationary and virtual cycling. The goal of this case study was to explore how incorporating Hydesign into novel 3D modeling workflows could accelerate design iterations and improve the feasibility of bike saddle paddings.
The outcome demonstrated the effective integration of these workflows within a limited budget, contributing to the exploration and implementation of new approaches in 3D concept modeling and prototyping.
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đź’ˇ I speak up for what I believe in: democratizing access to lattice generation and additive manufacturing technologies is the way forward.
Introduction
This project was conducted independently as a small part of my self-financed research aimed at addressing the challenges of prolonged seated pedaling, particularly in stationary and virtual cycling. The purpose of this case study was to explore how incorporating Hydesign into novel 3D modeling processes could accelerate design iterations and improve the feasibility of bike saddle paddings.
The outcome demonstrated effective integration of these workflows within a contained budget, contributing to the exploration and implementation of novel approaches in 3D concept modeling and prototyping.
Multi-material saddle. Material Jetting and Powder Bed Fusion additive manuifacturing technologies open endless possibilities in development of custom ergonomic seating applications. Copyright 2024 © David Alby Medina. All Rights Reserved.
Challenge
In continuation to my Masters Thesis project, where I studied the integration of ergonomic design principles, research methodologies, and novel concept modeling processes to develop a bicycle saddle that provides improvements in comfort and safety during prolonged stationary pedaling, I needed to further optimize and develop functional lattice structures for various designs and materials. After the studying period finalized, I struggled with limited resources and time constraints, leading to a cycle of endless iterations and challenges in creating functional, feasible designs. The complexity of traditional 3D modeling and limited material access added to the difficulties. Budget constraints further limited potential partnerships for reliable supplies. Indeed, I was simulating a real life use case to be able to come to realistic outcomes. I have tested various implicit modeling and lattice generation tools within short periods of time due to trial limitations; some were limited to proprietary materials and fabrication methods, others were not cost-effective and overlooked smaller users. Managing the entire process alone, especially trying to print prototypes that were fairly close to end-user grade standards, proved extremely challenging.
Methodology
First of all I am not an engineer, so apologies in advance if I share some innacuracies.
I developed several design iterations of bike saddle paddings by combining traditional polygon modeling techniques with implicit modeling techniques using Hydesign software (refer to figure 1), alongside with lattice pad (Lattice Application Discovery Kit) from BASF. This innovative concept modeling approach supported by real life sample references allows to create detailed functional designs, resulting in clean 3D models ready for 3D printing without the need for further editing.Â
I adopted Powder Bed Fusion (HP Multi Jet Fusion) and Vat Photopolimerization (MSLA) additive manufacturing methods, with a broad use of materials, such as TPU01 powder, as well as tough and elastomeric resins from BASF Ultracur3d product line.
I developed several design iterations of bike saddle paddings by combining traditional polygon modeling techniques with implicit modeling techniques using Hydesign software (refer to figure 1), alongside with lattice pad (Lattice Application Discovery Kit) from BASF. This innovative concept modeling approach supported by real life sample references allows to create detailed functional designs, resulting in clean 3D models ready for 3D printing without the need for further editing.Â
I adopted Powder Bed Fusion (HP Multi Jet Fusion) and Vat Photopolimerization (MSLA) additive manufacturing methods, with a broad use of materials, such as TPU01 powder, as well as tough and elastomeric resins from BASF Ultracur3d product line.
Figure 1. Brief representation of hybrid 3d modeling process, From polygon modeling to Hydesign. Copyright 2024 © David Alby Medina. All Rights Reserved.
Compatibility with 3d printing materials and methods
Besides the saddle pads printed in Ultrasint® TPU01, I used a variety of UV resin printing materials that previously I was not able to use with satisfactory results during my masters thesis project, so I decided to give them a go. Surprisingly, besides small adjustments in slicer to secure the 3d printing process, the samples printed fairly well on a consumer grade 3d printer (Anycubic Photon Mono X).
Printing complex large parts with TPMS and strut-based lattices generate with consumer grade 3d printers is not an easy task, requiring from a lot of trial and error until achieving reliable and consistent results. It is fair to say that getting access to generative algorithms that process seamless supportless lattices it greately contributes to such results.Â
However, I must admit that I could not handle properly the post-processing of the lattice pads being printed in resin, resulting in non durable parts. Some of the prints did not cure properly, and some required from leaving the parts outdoors for a while to get rid of the resin smelling.
Printing complex large parts with TPMS and strut-based lattices generate with consumer grade 3d printers is not an easy task, requiring from a lot of trial and error until achieving reliable and consistent results. It is fair to say that getting access to generative algorithms that process seamless supportless lattices it greately contributes to such results.Â
However, I must admit that I could not handle properly the post-processing of the lattice pads being printed in resin, resulting in non durable parts. Some of the prints did not cure properly, and some required from leaving the parts outdoors for a while to get rid of the resin smelling.
It was found that the biggest challenges we might face from resin printing methods including close propietary methods based on continuous vat photopolymerization, is not about the production itself, but rather from the assembly process, when padding must perfectly conform to the three dimensional surfaces of the shell body structure.Â
For that purpose, specific internal processes might be required during thermal curing cycle which is when the bonding or lets say the complete curing of the 2 part resins is achieved. In essence, the forming process of the padding to be fully adapted onto the shell surface can be (hypothetically) achieved during the thermal curing cycle inside a chamber or oven. In summary, while continuous vat photo-polymerization presents promising advancements, the process introduces too many challenges, specially when it comes to printing functional parts on a budget.
Pressure mapping. I use pressure mapping data only to get qualitative and visual feedback, due to lack of skills and resources to calibrate the system. In this regard, from the early concept phase prior to this collaboration, I use pressure mapping to support saddle selection (Figure 2). This information helps me to develop the saddle shell structure, while overtime getting a better understanding of the pelvic profile of each individual.
The lattice structures help to improve pressure distribution on the surface of the saddle and minimize maximum stress contact points, providing more comfort to the rider. The aesthetics of the lattices are considered wherever possible.
Figure 2. Comparison of pressure mapping data between male and female persons. Software used: Sensing Mat. Copyright 2024 © David Alby Medina. All Rights Reserved.
My approach to bike saddle design starts with getting to know the user. Once I have analyzed the collected information, I define the project's direction and begin the ideation phase. In this collaboration project, I continued to prioritize the prototyping cycle (see Figure 3 below). This involved continuously iterating through design phases, testing prototypes, and refining them based on feedback. By emphasizing this iterative process, I was able to efficiently detect and resolve issues, drastically reducing the time required for each iteration cycle. Despite innacuracies resulting from quick design iterations in Hydesign, the models were successfuly printed in resin materials.
Figure 3. Stages of product development with focus on prototyping cycle.
Copyright © 2024 David Alby Medina.
Copyright © 2024 David Alby Medina.
To accelerate design iterations, I purchased a Lattice Application Discovery Kit along with a library of pre-validated lattice structures available in Hydesign (Figure 4). This significantly streamlined the concept development process for certain design variants.
Since I intended to use a specific lattice type within the saddle padding, the purchase was well worth it in this case. Having a physical sample provided a tangible reference, allowing me to better understand the lattice configuration in real life. This approach proved highly effective as a starting point, particularly since I was still unfamiliar with the material and lattice behavior. It ultimately saved me multiple design iterations.
While I had already selected TPU as a suitable material for my saddle design, I also experimented with prototyping saddle padding variants using a wide range of resin materials.
Overall, rapid resin printing greatly improved the shapes, proportions, and feasibility of my designs. It enabled testing with functional materials within a relatively short timeframe, helping refine the overall design process.
Figure 4. Working with Lattice Application Discovery Kit and Lattice Library. Copyright 2024 © David Alby Medina. All Rights Reserved.
Discussion
In recent years, implicit modeling technology has begun influencing various industries, with the potential to revolutionize current methods. In 2020, during my design master’s thesis on a saddle project, I experimented with a combination of implicit and polygon modeling techniques. Although I had access to advanced modeling software through student licenses, I encountered two primary obstacles:
In recent years, implicit modeling technology has begun influencing various industries, with the potential to revolutionize current methods. In 2020, during my design master’s thesis on a saddle project, I experimented with a combination of implicit and polygon modeling techniques. Although I had access to advanced modeling software through student licenses, I encountered two primary obstacles:
Design Feasibility – I could not design practical, strut-based conformal lattices for my saddle pads.
Prohibitive Cost – After the student license expired, the software became too expensive to maintain.
These challenges restricted further exploration, as the tool was both complex and costly while failing to address my core design needs. In an increasingly automated work environment, devoting excessive time to technicalities is often inefficient.
A few years later, seeking a more viable and affordable option, I discovered Hyperganic and their lattice tool, Hydesign. Taking part in the beta testing program brought substantial value to my saddle project. Notably, the Hyperganic team’s user-focused approach and receptiveness to feedback stood in contrast to experiences with larger companies, which sometimes ignore smaller clients.
Hydesign provided a cost-effective and efficient solution for early-stage development, improving padding designs and reducing iteration times without reliance on expensive, complex software. Although it has yet to achieve fully seamless conformal lattice generation, it offers a practical compromise, creating functional lattices rapidly and expediting the prototyping phase.
Combining multiple modeling techniques polygon/subdivision, surface, parametric, and implicit modeling can establish a robust digital toolkit for concept modeling, particularly when working on lattice structures and prototype components.Â
For designers and engineers seeking an economical and effective way to accelerate design iterations, Hydesign is worth considering. Under tight deadlines, its pre-validated, support-free lattices proved highly efficient, and the ability to choose different materials and printing methods further streamlined the process.
Looking forward, adaptability remains essential as more disruptive, automation-centric tools emerge. The ongoing development and integration of these technologies will shape future workflows, underscoring the importance of staying versatile and receptive to innovative solutions.
Product Evaluation
Pros đź‘Ť :
Pros đź‘Ť :
• Cost-effective lattice generation tool that speeds up design and prototyping.
• User friendly with fast learning curve.
• Reduces iteration times and enhances creativity without the hassle from technical complexities.
• Compatibility with (mostly) any 3d modeling tool.
• Real democratization of lattice design without relying on expensive software or hardware equipment.
 (softwares such as Blender and FreeCad can be used, in combination with user grade 3d printers and materials).
 (softwares such as Blender and FreeCad can be used, in combination with user grade 3d printers and materials).
• Excellent customer support with a user-centered approach; Hyperganic Development team actively listens to user feedback.
• High-demand computing operations are performed on the cloud in just a few minutes, eliminating the dependence on high-performance local hardware.
• Versatile with material compatibility, supporting project adaptability and supplier independence.
• Easy access to specific materials from specific suppliers. (Might be Recommended in certain cases, but not limited to those).
• Fairly extensive lattice library to play with!
Cons đź‘Ž :
• While offers fast overall good results, it presents several technical limitations requiring from dedicated solutions or services.
• Does not yet (June 2024) offer fully seamless conformal lattice generation on irregular, non-flat surfaces. Â
• A more extensive lattice and material library would be beneficial in future updates. Update. And there we have it!
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Important Notice
This is a self financed publication, not an sponsored publication.
The content in this publication is part of my self-financed research focused on addressing the challenges of prolonged seated pedaling, particularly during stationary and virtual cycling scenarios. Resources have been provided by myself, excepting Hydesign license due to beta testing, as well as printed saddle pads in TPU01 from BASF Forward AM. Hydesign provided a beta testing license and user feedback without any participation or rights over in the design and development of the saddle.Â
The content in this publication is part of my self-financed research focused on addressing the challenges of prolonged seated pedaling, particularly during stationary and virtual cycling scenarios. Resources have been provided by myself, excepting Hydesign license due to beta testing, as well as printed saddle pads in TPU01 from BASF Forward AM. Hydesign provided a beta testing license and user feedback without any participation or rights over in the design and development of the saddle.Â
Copyright Notice
All images and content, including all saddle-related material showcased in the video published by Hyperganic, are under the authorship and private property rights of David Alby Medina, except for the video editing, third-party logos, and turnaround visualization of the lattice padding. These elements are included solely to acknowledge collaborations. All designs presented in any format remain under David Alby Medina's full intellectual property rights. Unauthorized distribution, modification, or commercialization of this content, in whole or in part, is strictly prohibited without explicit written consent. Any violation may result in legal action.
Portfolio Disclaimer
This website is a showcase of my design work and personal projects. Please note that I am not a company, freelancer, or sole trader. Although some projects may appear to be commercial, they are entirely my own creative endeavors. Any mention of copyright reflects my rights to protect my original work under applicable law. This site is not intended for selling products or representing any business; all content is presented solely for demonstration purposes.