Ergon Equine has partnered with
igus UK to develop a new saddle tree design that aims to improve horse welfare and rider performance through the use of custom 3D printed components.
The equestrian technology specialist has incorporated bespoke ball joint mechanisms produced using igus materials and engineering expertise into its latest BioTree saddle concept, a product designed to provide greater flexibility and movement than conventional saddle tree designs.
Ergon Equine develops equipment intended to enhance both equestrian performance and comfort. Its current NewTree range features an injection-moulded saddle tree with customisable elements from gullet to cantle. The company’s BioTree design builds on this approach by offering a dynamic alternative to traditional saddle structures.
Conventional saddle trees are typically manufactured from laminated wood reinforced with metal plates. These components define the shape of the saddle and determine how loads are distributed across the horse’s back. Achieving an accurate fit is therefore critical for both equine comfort and riding performance.
However, the static nature of wood and metal limits movement within the saddle structure. Ergon Equine sought to overcome this challenge by developing a design capable of moving with the horse while remaining lightweight, durable and maintenance-free.
“With BioTree, we’re trying to develop a tree that moves with the horse, and within the saddle industry, that wasn’t really something that was being done,” said Bjorn Hulman, Head of Design at Ergon Equine.
Following the evaluation of standard igus components during the prototype phase, the company worked with igus UK to create a customised solution tailored to its performance requirements.
The resulting design incorporates six ball joint mechanisms featuring stainless steel ball studs combined with 3D printed housings. The assemblies are designed to withstand varying loads, temperatures and operating conditions while enabling the dynamic movement required between horse and saddle.
The housings were manufactured using iglidur® i230, an igus selective laser sintering (SLS) material developed for high wear resistance and mechanical strength. According to igus, the material offers significantly greater wear resistance than conventional PA12 alternatives while also providing strong flexural properties and electrostatic dissipation characteristics.
The completed solution allows movement across three axes and delivers the rotational capability required to support both rider performance and horse comfort.
igus says the use of wear-resistant materials and robust component design contributes to increased reliability and product longevity, helping to meet the demands of professional riders and regular use.
Ergon Equine also believes the technology can play a role in improving equine welfare by allowing the saddle tree to respond more naturally to the horse’s movement, reducing restrictions that can occur with more rigid designs.
“We came across igus as we were looking for a hardware supplier that could meet our specific performance requirements,” said Ginny Heggie, Director at Ergon Equine. “They work really well for us, giving us the exact rotational capacity we need.”
By integrating advanced motion plastics technology into its BioTree design, Ergon Equine has developed a low-maintenance and durable solution that aligns with its goal of delivering innovative products to the equestrian sector. The collaboration demonstrates how additive manufacturing and custom-engineered components can be applied beyond traditional industrial markets to address performance and welfare challenges within the equine industry.