Case Study: Specialized achieves 2x faster product development and breakthrough saddle comfort with Carbon

Specialized Innovates at 2x the Speed with Carbon

Specialized, the longtime performance bicycle brand, faced a design limit: traditional foams couldn’t deliver the variable density and zoned support riders need for both comfort and control. Working with Carbon and its Carbon platform, Specialized explored elastomeric lattices and Carbon’s EPU family to find a material and process that would let them tune cushioning, energy return, and stability across the saddle.

Carbon delivered an end-to-end solution using elastomeric lattices (EPU 41 Black) printed on the Carbon platform, a compression-gradient lattice design, and a novel excimer-lamp surface finish to add grip. The result: validated lower peak pressure and smoother pressure distribution on pressure maps, overwhelmingly positive rider feedback, and a scalable production process (L1 printer, solventless post-processing). Carbon helped Specialized cut development time from 24 months to 10 months while moving the S‑Works Power Saddle with Mirror into production.

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