Commercial applications of 3D printing on bicycles include bicycle frames, stems, handlebars, saddles, and helmets. The future of 3D printing is here, and it's time for a change.
Frame
In June 2022, the new 3D-printed bicycle frame New01bike debuted at Milan Design Week 2022. It was designed by INDEXLAB and produced by GIMAC-EXGINEERING. The material came from 100% recycled polycarbonate and was 3D printed with a 6-axis robot.
The frame of this bike is 3D printed from recycled polycarbonate aka PC plastic with a transparent effect and requires high impact resistance. A Robotic Additive Molding 6-axis robot was chosen for production. The entire frame is integrally formed and weighs about 8 kg.
Stem
In June 2022, MYTHOS from the UK announced the launch of the world's first commercial version of the MYTHOS ELIX stem.
This 3D printed stem uses a special high-strength Scalmalloy alloy material containing scandium, aluminum, and magnesium, which has 15% higher torsional stiffness than equivalent alloy stems while maintaining the same bending stiffness. In addition, a hollow design is also used to eliminate high-stress areas through small local reinforcements and cleverly remove any non-essential material to reduce the weight of the entire vehicle.
In addition to making stems for standard bikes, MYTHOS has also developed a 3D-printed stem called IXO specifically for mountain bikes.
Using the most advanced EBM additive manufacturing technology, it is made of aerospace-grade titanium alloy (Ti6Al4V). In a side-by-side test with an equivalent alloy stem, it was 16% more torsional and 11% more flexural.
Handlebar
The TX-1 is a 3D-printed titanium rail handlebar, also from MYTHOS.
Designed for mass start races, the TX-1 is 3D printed using EBM (Electron Beam Melting). It takes advantage of the new UCI regulations that allow the handlebars to overhang 10cm in front of the front axle. By allowing 6 hand positions, the TX-1 significantly increases rider options to maximize aerodynamics, rider mobility, and comfort.
Seat
In April 2022, Fizik launched the new Argo Adaptive 3D printing short nose cushion.
Developed based on the existing Fizik Argo short-nose seat cushion version, there are 2 models to choose from, namely R1 with carbon fiber rails and R3 with Kium hollow aluminum rails. These two cushions use 3D printing honeycomb carbon composite material to replace the traditional closed-cell foam cushion, and the 3D printing honeycomb surface is covered on the carbon fiber bottom plate. Manufactured using Carbon's Digital Light Synthesis (DLS) 3D printing technology.
In April 2022, shortly after Fizik released the 3D printed cushion, Specialized also launched its new 3D printed cushion Power Pro, which is also the company's third 3D printed cushion.
Power Pro still chose to cooperate with Carbon. The pad uses a 3D printing complex honeycomb structure, which can better control the pad density and provide more support and comfort than traditional foam.
Helmet
In April 2022, KAV Sports launched an upgraded version of the 3D printing bicycle helmet.
Using 3D printing, they created a honeycomb structure and added additional reinforcement in key areas, such as tubular cylinders where the seals meet the front vents. This design better protects the rider's head in the event of an impact and also allows for good ventilation at the front of the helmet. According to KAV, their helmets exceed helmet certification standards by 25% and are safer.
In August 2022, Berlin-based manufacturer nFrontier debuts a revolutionary new bicycle helmet, the PYLO.
Different from traditional helmets, nFrontier used 3D printing to make the inner lining of the helmet shell for the first time, which not only makes the helmet lighter and has better wearing comfort, but also, when the helmet is hit by an external force, its cushioning force can be more powerful Disperses efficiently to protect riders. It is understood that the company chose 3D printing manufacturer Stratasys' F370 and J55 3D printers for production.
As time goes by, 3D printing will have new uses in more traditional fields, we will wait and see.