Bicycle saddle and method for making the same

A method for making a bicycle saddle, comprising the steps of:

• a) providing a mold defining a mold cavity therein;
• b) positioning a core insert in the mold cavity, the core insert having an upper major surface and a lower major surface;
• c) positioning a stack of fiber fabrics in the mold cavity to permit the stack of fiber fabrics to be retained on the upper major surface of the core insert;
• d) positioning two bundle segments of a braided fiber bundle in the mold cavity to permit each of the bundle segments to be retained on the lower major surface of the core insert and to be arranged in a front-rear direction such that two front end regions of the bundle segments are in contact with each other and extend out of a front edge of the core insert to be brought into contact with the stack of fiber fabrics, and such that two rear end regions of the bundle segments are spaced apart from each other and extend out of a rear edge of the core insert to be brought into contact with the stack of fiber fabrics;
• e) introducing a curable resin material into the mold cavity to impregnate the stack of fiber fabrics and the braided fiber bundle with the curable resin material;
• f) after step e), molding the impregnated stack of fiber fabrics and the impregnated bundle segments in the mold to cure the curable resin material so as to permit the impregnated stack of fiber fabrics to be molded into a shell and to permit impregnated bundle segments to be respectively molded into two rails connected to the shell, thereby obtaining the bicycle saddle;
• g) removing the bicycle saddle and the core insert from the mold;
• and
• h) removing the core insert from the bicycle saddle.