Catalyst

What it does

Catalyst solves issues with saddle-fit and impact-related discomfort in show jumping using 3D-scanning and printing technologies. Its carbon fiber structure is lightweight, shock-absorbent, and crafted for the individual.

Your inspiration

I am a lifelong equestrian and have always noticed and experienced saddle-related issues with comfort and communication between horse and rider. When I considered the current problems with saddles and our relationship with them, I thought - What if we changed the way we make saddles? The idea of merging modern technology with the traditional saddle-making craft is what inspired me from the beginning. Not only is the stagnant saddle industry a great opportunity space for innovation, but making a saddle that performs better would have a positive impact on the sport as a whole.

How it works

By 3D scanning the horse using Lidar technology, the animal is brought into CAD. The saddle is modeled around the horse's back for a precise custom fit. The structural component of the saddle, or the "saddle tree", has a parametric design for lightweight shock absorption. This lattice structure is made using Grasshopper and 3D-printed in carbon fiber. In addition to the structure of the saddle, the cushions in the saddle are custom-modeled for the individual and printed out of TPU. The patterns for the leather are custom-made in CAD, and the leather is laser-cut. Sewn with the help of saThe minimal parts are assembled with Chicago screws for sustainable ease of manufacturing.

Design process

I began the process by doing thorough secondary and primary research on the relationship between horses, riders, and their equipment. I did a teardown of an existing saddle that gave me insight into how they are made. I explored new technologies being used in other industries that could be applied to saddle making. I got expert opinions from coaches and professional riders. I sketched designs prioritizing shock absorption, fit, and modern aesthetics. After narrowing my concept, I practiced 3D scanning horses and worked to learn Grasshopper for parametric design. I did CAD iterations for the saddle structure and printed small-scale models. I printed the horse's back that I scanned to test the fit of the structure I created. Alexa Chepolis helped with the leather work for the project, and together we experimented with different techniques and created mock-ups for different pieces of the saddle. In just 10 weeks, I went from concept to full-scale mock-up. I then spent 10 additional weeks re-evaluating my design and pushing it farther in its sustainability, CMF, form, and function. For the final model, the structure was 3D printed in one piece, the leather was laser cut for precision and hand-dyed, and I used Chicago screws to assemble the parts without glues.

How it is different

Unlike current saddles on the market, Catalyst is made using 3D printing and scanning technologies. Most saddles create problems due to poor fit, and their heavy and outdated materials fail to absorb shock. Catalyst has a custom lightweight carbon fiber lattice structure that sets it apart. Most saddles are measured by hand, which is inconsistent and reliant on trained representatives. Catalyst is modeled for the individual with precision using 3D scanning. Most saddles are complicated to make and require years of expertise to construct. Catalyst is made with laser-cutting technology and minimal, easily assembled parts.

Future plans

In the near future, I intend to develop a functioning prototype of Catalyst. My goal is to refine the design and material choices with user testing of a working model. After this testing, I hope to create a version of the product which has the potential to go to market.

Awards