Short version cliff notes: Through additive manufacturing we make any custom pad in any shape, size with variable density. How we distribute those articulated cell foam strands offsets the common ‘pain zone’ pressure mapping areas in both our road pad or aero pad - depending on application. You are riding on a state-of-art product. It works.
We worked hard to find a manufacturing partner that we could collaborate with to make our custom pads. We created CAD files for the top 10 tri-saddles, overlaid the shapes and then removed a few outliers. That combination got us perfect map for about 90% of what athletes are using in the aero position. Next, we studied how athletes were sitting on those saddles. It became very obvious where the pressure was (pain zones), where pads were lacking coverage/density and what we needed to do to solve the problem.
Then we applied existing technology to our new design to move moisture away from the athlete. By designing hydrophobic and hydrophilic properties within the pad materials; the passage of moisture from the inside to the outside is constant. The system transports moisture away from the athlete and adds to comfort as well as removing bacteria filled moisture away from sensitive skin. Moisture is a huge contributor to saddle sores.
Both our road bike pad (sewn in the traditional position) and our aero bike pad (sewn in the aero position) shapes, contours and varying densities are manufactured with 3 types of open reticulated cell foam strand: 75 density (kg/m³), 120 density (kg/m³) and 100 density (kg/m³) with a total thickness of 16mm. How those foams are distributed offsets the common ‘pain zone’ pressure mapping areas in both the road pad or aero pad depending on application.
For cover fabric (the side that touches your skin) we use polyamide (80-82%) and elastane (18-20%) with a “soft-brush” finish that gives a soft and pleasant touch. That fabric is also treated with an antibacterial and hydrophilic process - pulling moisture.
Thanks to the latest 3D print and shape/shave technologies - CAD files are created to model specific shapes, sizes and contours with varying density; allowing the build-up of different densities and characteristics within one pad. No hot melting, gluing or sewing foam stacks together.
You are riding on a state-of-art product. It works.