Pogačar rides for 5th Tour de France title on custom 3D-printed saddle

Full text

It goes without saying that it takes a lot to win the Tour de France , as those who conquer cycling's greatest race have scarified so much in their quest for glory, with every single second counting.

The 2026 race has already started strongly for Tadej Pogačar and his UAE Team Emirates-XRG team, with the Slovenian building a seemingly unsurpassable lead as he bids for his fifth triumph.

But asides from his incredsible physiology and stamina, Pogačar is also boasting another major advance for the 2026 Tour - a customized 3D-printed fizik One-to-One saddle, possibly the most detailed ever made - I spoke to the company to find out more.

Marginal gains

"Small details in the technology might make the difference," Alex Locatelli, Head of Brand at Fizik says, "the marginal gains in this case - comfort is strictly related to performance, as if you are able to forget about this, it's less thought you need to give while you have to focus on another part of training and racing."

3D-printed and adaptive saddles have been around for some time, but Fizik's one-to-one product goes beyond a standard mould, using the company's proprietary pressure-mapping sensor technology (pictured below) to create a hyper-customized product designed specifically for an individual rider's anatomy and riding style.

(Image credit: fizik) Locatelli notes each saddle takes around two to three weeks to produce, but certain VIPs (such as a multi-Tour winner) can get their products rushed through.

"We have a very good relationship with Tadej," he says, "that's something that's not easy to achieve...as a matter of fact, the team principal told me it's very rare that Tadej is so enthusiastic about a product - sometimes he's not even happy after winning the Tour de France, he's so demanding to the team and to himself."

"We are offering thr top of the pyramid when it comes to the technology," Locatelli says, noting that the saddle may be the next in a series of upgrades used by Pogačar that his rivals may soon look to copy.

Tadej Pogačar's unique One-to-One saddle (Image credit: fizik) But even the standard saddles Fizik produces in the future will benefit from the pressure-mapping data the company is collecting now, as it all goes in to future production and product development.

The technology is so precise and advanced right now that it may be a while before we see such innovations trickle down to us everyday cyclists, but I have to ask Locatelli if there's a future for park cyclists like myself ever getting hyper-personalized 3D-printed components.

He notes that it may take a few years, but adds, "general customization in cycling is expanding," highlighting how some smaller manufacturers are offering more options in terms of custom frames and saddles.

So you never know - the next bike you buy could be the most personal ever - but it might not let you ride quite as fast as Tadej Pogačar.

And an AI-designed helmet for good measure

However Pogačar won't just have fizik's individually-sculpted saddle to help him try and win this year's Tour. For stage 5 of the 2026 race, UAE Team Emirates-XRG also revealed a new helmet designed by AI.

Specifically designed by Helmetverse, the AI-powered design platform of tech group and team sponsor G42, and built by MET Helmets, the helmet was created in collaboration with AI artist Gizem Akdag, who says they were, "inspired by the transition from city to signal and from data to light", as the kit's "visual language captures the speed, energy and flow of professional cycling, translating movement and performance".

(Image credit: G42) “The reaction to Helmetverse last year showed how passionate cycling fans are about engaging with our sport in new ways. As a team, we are always looking to push boundaries, whether that's through performance, innovation or fan engagement," said Mauro Gianetti, Team Principal and CEO of UAE Team Emirates-XRG. "Helmetverse reflects that mindset and gives cycling fans an opportunity to leave their mark on the team.”

Fans of the team can also now submit their own helmet designs, including creating their own using Helmetverse AI, with the winning design worn by UAE Team Emirates-XRG at the UAE Tour in February 2027.