The bike saddle has earned her awards, recognition, and a dream internship to ride to a future in material design.
Julia’s project was born from her own experience as a cyclist. “I struggled to find a comfortable saddle, so I wanted to create something that addresses that issue while also exploring how 3D printing could be used to achieve customised product design.
“The Vauxel saddle combines pressure mapping with advanced 3D printing techniques to create a design that fits to a cyclist’s unique contours,” she explains. “The design blends rigid and flexible materials to fit a cyclist’s unique contours, while auxetic materials, which expand when stretched and contract when compressed, enhance comfort by responding to movement.
“The novelty of this saddle concept is its integration of auxetic materials and a data-driven design process. Vauxel is based around droplet-level control during the 3D printing process, which is used to create zones of varying flexibility that are tailored to match a rider's unique pressure distribution pattern.”
The Vauxel saddle won a silver award in the Designers Institute of New Zealand Best Design Awards and was shortlisted for the Global Creative Graduate Showcase 2024. In addition to her awards, she has connected with academic leaders in the field, even speaking on her design with Manchester Metropolitan University and securing an internship with Velobike Innovation.
“I’ve wanted to pursue manufacturing and industrial design, so this is a great opportunity. Velobike produces bikes, including ones used at Olympic level, so it will be exciting to work in that high-level space. I’ll also get to tackle design challenges—something I’m really looking forward to.”
Julia’s path to design wasn’t linear. Initially torn between studying biology or anthropology, she discovered her passion for design innovation accidentally. "I wasn't sure what industrial design really was when I first started," she admits, "but it sounded interesting, and I liked the idea of creating something physical."
Her interest grew as she realised the potential to make user focused, customised designs. “I believe the future of design lies in personalisation, where products are tailored to the end user. I want to help drive that shift.”
Collaboration has been key to Julia’s success, especially when navigating new and challenging research spaces. When a professor encouraged her to take on a summer research position, she embraced the opportunity despite the steep learning curve. Transitioning into this new territory required Julia to learn new software and ways of designing, along with the technical literature surrounding designed materials.
Rather than being discouraged, Julia saw these challenges as a chance to expand her skill set. “Diving into research gave me the tools to approach complexity with curiosity and persistence,” she explains. This mindset led her to contribute to two innovative projects that significantly influenced her approach to design.
“The first project explored a new 3D printing method using liquid as a support material, making it easier to create complex structures with unique properties and removing the need for tedious post printing cleanup.
“The second project focused on using advanced 3D printing to combine multiple materials within a single object, enabling the creation of products with novel and unique properties—an area the University leads in. This research was ultimately the foundation for Vauxel.”
Her academic journey was also shaped by her involvement in Te Kura Hoahoa—School of Design Innovation’s vibrant community. As a tutor during her time at the University, Julia gave back to her peers. “When I was an undergraduate student, I was intimidated by the software involved in this specific course. As a tutor, I tried to replicate the support I received, helping students step-by-step and providing encouragement.
“It was also great to collaborate with the lecturers in a different way. During your undergraduate degree, you get to know them in one context, but seeing the other side was interesting, and having your ideas and opinions valued when it comes to courses and programmes is incredibly validating.”
As Julia prepares to graduate, she reflects on the best moments of her journey. “My biggest win has been creating something I truly wanted to produce, combining design, material science, and 3D printing. It’s all been very rewarding.”
Her advice to future students is simple, “Be open to opportunities and get involved, even in areas you might not initially feel comfortable with. And apply for summer scholarships—they were pivotal for me.”