Process for manufacturing a bicycle saddle

PROCESS FOR MANUFACTURING A BICYCLE SADDLE, which provides a central through channel and which has:

• a hull with a through hole at the central through channel of the saddle;
• a polyurethane layer as a padding element;
• a liner adapted to cover the polyurethane layer, said process providing for the following steps:
• arranging the liner on the hollow surface of a mould;
• creating a vacuum between the liner and said hollow surface to allow adhesion between the liner and the hollow surface;
• pouring polyurethane into said hollow surface;
• positioning the hull on the surface of a counter mould;
• moving the mould towards the counter mould and consequent positioning of the counter mould at the hollow surface of the mould;
• expansion of the polyurethane, which completely fills the space between the liner and the hull;
• moving the mould away from the counter mould;
• extraction of the hull, the polyurethane, and the liner of the mould, wherein said liner is subjected to a previous processing step so as to present a cap-like structure at a region in which the channel of the saddle will be present once formed and in that the step of arranging the liner presenting the cap-like structure on the mould takes place taking care to arrange said cap-like structure on a projection provided in said mould, wherein the projection is adapted to engage with a concave portion of said counter-mould;
• said process wherein, at the end of all the previous steps, a portion of the cap-like structure on the projection and which protrudes above edges of the hole of the hull is removed and said liner is made by the following steps:
• creating a hole on a semi-finished liner, at the region where the channel of the saddle will be present, once formed;
• -welding of a cap-like structure to the semi-finished liner at the hole, so that open edges of the cap-like structure coincide substantially with the edges of the hole.