###### Abstract  
Design for additive manufacturing (DfAM) has made significant advancements in recent years, with development focusing on pivotal aspects such as topology optimization (TO), generative design (GD), lattice structures, and AI-based algorithms. This paper puts forth a proposed methodology for the development of customizable bike saddle pads for manufacturing with AM. The approach entails the selection of appropriate AM processes and materials, the evaluation of material properties through compression testing, an initial saddle pressure mapping and bike fitting, the design and AM of bespoke saddle pads based on the initial measurements, and a validation pressure mapping and bike fitting. The investigation yielded clear findings regarding improvements in both pressure distribution and the change in pressure peaks, as well as an improvement in riding comfort. The findings indicate that although the overall process is innovative, improvements are required to streamline the measuring, modeling, and manufacturing workflow. Keywords:additive manufacturing (AM); design for additive manufacturing (DfAM); lattice structures; CAD; road bike saddle 2020 ac  
of both metals and polymers is employed in applications pertaining to the aerospace and automotive industries, and it is regarded as the most effective approach [10,11]. The implied design freedom and the freedom of form of AM are significant drivers in the development of parametric CAD solutions such as nTopology nTop [12], Altair\({}^{\circledR}\) Sulis\({}^{\circledR}\)[13], Altair \({}^{\circledR}\) Inspire\({}^{\circledR}\)[14], Carbon\({}^{\circledR}\) Design Engine Pro [15], Autodesk Netfabb Ultimate [16], and Metafold [17] currently available on the market. Design mechanisms such as topology optimization (TO), generative design (GD), and lattice structures are commonly used in conjunction with AM to reduce weight and material cost and simultaneously maximize the stiffness or flexibility of part designs. Cellular materials are frequently encountered in nature in the form of sponge and coral structures, as well as wood and trabecular bone material. In biological systems, these structures are composed of prismatic or polyhedral networks of solid struts or plates, which serve to define the edges and faces of individual cells, thereby filling space and bridging distances [18]. [PERSON] and [PERSON] proposed that cellular structures encompass open cells, as well as closed cell foams, honeycombs, and lattice structures. However, the latter differs from honeycombs and foams in that the cell topology, scale, and properties are defined differently [19]. In the industry, cellular structures are made from metals, polymers, ceramics, or glasses [18]. The term lattice structure derives from the former more widely used term cellular structure, as it was originally proposed by refs. [20,21]. Lattice structures are currently under investigation or even employed in a multitude of industrial sectors, including aerospace [10,22], marine [23], and automotive engineering [24], as well as in the fields of medicine biomedical engineering [25] and the sports equipment industry [26]. All lattice structures, regardless of whether they are strut-based or surface-based, can be either constant or gradient and conformal or non-conformal. Their surface limit can either be straight/angled, described by a spline, or it can be defined as open. It is essential to consider and meticulously adjust all previously mentioned variables, such as unit cell topology [27], conformity [28], progressivity [29,30], surface limitation [19], and unit cell distribution [31] (periodic or stochastic), when designing applications in order to achieve a highly functional and resilient part with distinctive properties, manufactured using functionally graded strut-based lattice structures with both open and freeform surface limits. This contribution aims to present an innovative approach to the design of individually customized road bike saddle pads.