Innovation in equine saddle design with 3D printed ball joints

Traditional saddles offer no flexibility, are rigid and heavy. Ergon Equine wanted to explore the possibility of not only reducing the weight of an innovative saddle, but the height and the flexibility. Their current market offering, NewTree, is an injection moulded tree design offering a range of customisable features from gullet to cantle. The latest product in development, BioTree, provides a dynamic, equine-centric alternative to traditional saddle tree designs.

Traditional saddle tree designs are often crafted from laminated wood and reinforced with metal plates. These trees dictate the shape and load-bearing points on a saddle, and as such, a perfect fit is essential to ensure comfort for the horse and optimal performance. Using unforgiving, static materials such as wood and metal restricts the possibility of dynamic movement, something Ergon Equine were determined to change with their injection moulded tree offerings.

To achieve this goal, a lightweight, robust and maintenance-free solution that could facilitate continuous movement was required.

After trying standard components from igus in their prototyping stages, Head of design, Bjorn Hullman sought for a customised solution that could encompass all their design requirements.

The solution that emerged was six 3D printed ball joint mechanisms with stainless steel ball studs that could withstand different loads, temperatures and intensities all while facilitating dynamic movement between the horse and saddle.

The housing was printed using iglidur® i230, a selective laser sintering (SLS) material from igus that is 80% more wear-resistant than its PA12 alternative. iglidur® i230 has the highest flexural strength of all the materials within its group and is also electrostatically dissipative, making it a strong all-rounder for other industrial applications.