igus UK Collaborates with Ergon Equine to 3D Print Saddle Trees to Enhance Horse Welfare

en.Wedoany.com Reported - Equestrian equipment company Ergon Equine has partnered with igus UK to integrate custom 3D-printed components into a new saddle tree design, aiming to improve horse welfare and rider performance. The ball-and-socket joint mechanism developed through this collaboration has been incorporated into Ergon Equine's latest BioTree saddle concept, which is designed to offer greater flexibility and range of motion compared to traditional saddle tree structures.

Ergon Equine specializes in developing equipment for equestrian performance and comfort. Its existing NewTree range features injection-moulded saddle trees with customizable elements from the gullet to the cantle. The new BioTree design builds on this foundation, offering a dynamic alternative to conventional saddle tree structures. Traditional saddle trees are typically made of laminated wood reinforced with metal plates, and their shape directly determines how load is distributed across the horse's back, making a precise fit crucial for horse comfort and riding performance. However, the static nature of wood and metal limits the range of movement within the saddle tree structure. Ergon Equine sought to address this with a design that moves with the horse while remaining lightweight, durable, and maintenance-free.

The company's Design Director, Bjorn Hulman, stated that the goal in developing BioTree was to create a saddle tree that moves with the horse—an approach rarely attempted before in the saddle industry. During the prototyping phase, the team first evaluated standard igus components before collaborating with igus UK to customize a solution that met their performance requirements. The final design incorporates six ball-and-socket joint mechanisms, combining stainless steel ball studs with 3D-printed housings, capable of withstanding varying loads, temperatures, and operating conditions while providing the dynamic movement required between horse and saddle. The complete solution supports movement across three axes, offering the rotational capability needed to support rider performance and horse comfort.

The joint housings are manufactured using igus's selective laser sintering (SLS) material iglidur® i230, which was specifically developed for high wear resistance and mechanical strength. According to igus, its wear resistance is significantly higher than that of traditional PA12 alternatives, while also offering good flexural properties and electrostatic dissipation characteristics. igus states that the use of wear-resistant materials and robust component design contributes to enhanced product reliability and service life, meeting the demands of professional riders and everyday use scenarios.

Ergon Equine believes this technology can also have a positive impact on horse welfare by allowing the saddle tree to respond more naturally to the horse's movements, reducing the restriction that rigid designs can cause. The company's Director, Ginny Heggie, noted that the team came into contact with igus while searching for a hardware supplier that could meet their specific performance requirements, and igus provided precisely the rotational capability needed, matching their demands closely. This collaboration demonstrates the potential of additive manufacturing and custom-engineered components beyond traditional industrial markets, while also offering new solutions to performance and welfare issues in the equestrian equipment sector.