3D Printing for Consumer Goods: Super-light Singlespeed Bike from the Printer

Optimal Frame Geometry, Simple Construction & Casual Design

The CT software developers combined self-constructed, 3D printed connecting parts made of aluminium (AlMgSi10) and machine-made, extremely light carbon tubes from the company Carbonforce. The tubes were joined using high-strength two-component adhesive from the aircraft industry.

The project was realised in a record time of only two months from the idea to the ready-to-ride prototype. The CT team optimised the design based on an existing 56 centimetre frame geometry and perfected it in numerous 3D renderings. Thanks to a clever design of the frame parts, the singlespeed version can also be upgraded with gears.

Thanks to the degrees of freedom made possible by computer aided design (CAD) in conjunction with the 3D SLS printing process, a particularly light and simple design was achieved that, thanks to its excellent riding characteristics, represents a counter-trend to technically complex and heavy e-bikes.

In this interesting project, the software manufacturer used its 4D_Additive software to optimise wall thicknesses, generate surface textures and realise the smooth production of the 3D printed parts on the SLM machine of the service partner FKM.

In numerous test rides, the 3D printed bike has proven that it is highly robust and resilient and can be easily moved on different types of paths. With the project and the resulting prototype, the CoreTechnologie team has shown that with the help of current software and hardware, the production of complex everyday and consumer items is possible in a cost-effective, fast and simple way, independent of fragile supply chains.

"In addition to the casual design and riding pleasure, CoreTechnologie's super-light bike put an incredulous smile on the testers' faces as soon as they picked it up," says visionary and CT CEO Armin Brüning, delighted with the latest CT development.