I bought my KH saddle about a year ago, a friend just got his the other day from unicycle.com (good bunch) along with a Nimbus II. There are the obvious differences in the design and material, but the shape of the new one is less rounded, and more comfortable.
Is this just a manufacturing difference or have they altered the design slightly?
This is a hard question to answer because everytime Unicycle.com and Bedford Unicycles orders a new batch of saddles, I’ve improved them a little bit.
That, by the way, is one of the differences between the KH-branded and the non-KH branded copies of the saddle. There are a lot of ways you can make the saddle for less money, such as by using a cheaper saddle cover fabric. For the KH branded saddles, because I use them too I want to ride on the best stuff so they tend to use the better quality materials, even though this makes them more expensive to make. The copies are OK in that some aspects are the same, such as the bumpers and the saddle frame.
Current saddles (the ones in stock right now) are stiffer and stronger than previous versions and have a more durable saddle cover, with a more durable taiwanese-made (as opposed to chinese made) kevlar fabric on the front and rear panels. The foam is reduced in width by 15mm in the front, to reduce chafing, and is slightly softer than previous versions.