This case study details how Selle Royal transformed saddle development using Altair Inspire PolyFoam simulation. Saddle manufacturing depends on precise polyurethane foam filling, where defects are costly and time-consuming to resolve experimentally. Selle Royal used simulation to analyze foam material behavior, injection timing, mold motion, and defect formation early in the design process. Engineers were able to predict short shots, weld lines, and material waste while optimizing comfort and durability. The virtual workflow significantly reduced physical testing, shortened development cycles, lowered costs, and enabled a more efficient, simulation-driven approach to saddle manufacturing.

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