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Gallery: How a Fizik saddle is made

Oct 10, 2016

How does Fizik make a saddle like this Italian-themed Antares? We took a Tour of the factory, near Vicenza, to learn more about the process, which, for the most part, is "fatto a mano" — done by hand. Photo: Spencer Powlison | VeloNews.com

The saddle shells are not produced at this Selle Royal-owned facility, but they are made in Italy, as are the saddle rails. Photo: Spencer Powlison | VeloNews.com

The first step in the process, adhering foam to the shell, is one of the most automated processes. This man places shells on the rotating assembly line, and the saddle moves to a booth where the proper foam is poured into the mold below, and the shell is lowered into the goo. Photo: Spencer Powlison | VeloNews.com

Fizik has shelves full of different molds at the ready. Photo: Spencer Powlison | VeloNews.com

After the foam is adhered to the shell, the excess material is removed by hand prior to the application of glue that holds the cover in place. Photo: Spencer Powlison | VeloNews.com

The three panels required to construct an Antares saddle are stamped out of a sheet of microtex fabric using a metal cookie cutter like this. Photo: Spencer Powlison | VeloNews.com

One feature unique to Fizik saddles is the Wing Flex, which allows the saddle to flex at the sides and minimize chafing. To achieve this, the microtex fabric must be cut using a 110-degree Celsius laser for 10 seconds. Photo: Spencer Powlison | VeloNews.com

After the Wing Flex cuts are made, an additional layer is bonded beneath to seal the saddle from the elements. Photo: Spencer Powlison | VeloNews.com

The three panels of microtex cover for this Antares are stitched together with remarkable efficiency. Photo: Spencer Powlison | VeloNews.com

The finished cover is strong and the seams are neat. They can stitch up to 100 saddles per hour, an impressive feat on what is essentially an industrial, hand-operated sewing machine. Photo: Spencer Powlison | VeloNews.com

The saddle cover installation is one of the most impressive steps in the process. This two-person team sets the cover precisely, in the center, with help from a laser guide. Three layers of glue are required to hold the cover in place. Photo: Spencer Powlison | VeloNews.com

Following the attachment of the saddle cover, the two-person team does a quick, preliminary trim on the excess microtex fabric. Photo: Spencer Powlison | VeloNews.com

Although the saddle cover team trims much of the excess material, a second step of the process thoroughly finishes the product, a delicate step that involves some careful knife work to avoid damaging the shell. Photo: Spencer Powlison | VeloNews.com

Although carbon rails only save 40 grams per saddle, Fizik representatives told us they are quite popular in the aftermarket as riders seek to upgrade their bikes with a top of the line option. They also require an additional day of production time. Photo: Spencer Powlison | VeloNews.com

To hold the rails in place, glue is injected into the appropriate ports on the saddle’s base. Photo: Spencer Powlison | VeloNews.com

If the saddle is slated for metal “Kium” rails, they are flexed and popped into place using this machine. Photo: Spencer Powlison | VeloNews.com

After the saddle’s rails have been installed, excess glue is cleaned up for a finished look. Photo: Spencer Powlison | VeloNews.com

Once the assembly is complete, a few final decals are applied, the saddles are tagged, and placed into boxes — by hand, of course. Photo: Spencer Powlison | VeloNews.com

A great deal of pride goes into making a saddle like this, signed by Olympic omnium track champion Elia Viviani. It’s no coincidence that Fizik chose to walk us through the process using a saddle with the tricolore of Italy. The process to make one saddle is about 72-78 hours, requiring about 50-70 steps in the manufacturing process. Photo: Spencer Powlison | VeloNews.com

The post Gallery: How a Fizik saddle is made appeared first on VeloNews.com.

Tags: Bikes and Tech fi'zi:k Gallery News

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