08/02/23

3D Printing for Everyday Items: Super-Light Singlespeed Bike from the Printer

Additive manufacturing and 3D printing have now become an integral part of industry and mechanical engineering.

Optimal Frame Geometry, Simple Construction, and Casual Design

The CT software developers combined self-designed, 3D-printed connection parts made of aluminum (AlMgSi10) with machine-manufactured, ultra-light carbon tubes from Carbonforce. The tubes were connected with high-strength two-component adhesive from the aerospace industry.

The project was realized in a record time of just two months, from concept to the rideable prototype. The CT team optimized the design based on an existing 56-centimeter 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 a gear shift.

Thanks to the design freedoms enabled by computer-aided design (CAD) combined with the 3D-SLS printing process, an especially light and simple design was achieved, which, with its excellent riding qualities, offers a countertrend to technically complex and heavy e-bikes.

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

Through numerous test rides, the 3D-printed bicycle has proven to be very robust and durable, and it can be easily maneuvered on various paths. With this project and the resulting prototype, the CoreTechnologie team demonstrated that with the help of current software and hardware, the production of complex everyday and utility items is cost-effective, fast, and easy, regardless of fragile supply chains.

Besides the casual design and fun ride, the super-light bike from CoreTechnologie brought an incredulous smile to the faces of testers as soon as they picked it up,” said visionary and CT Managing Director Armin Brüning, delighted with the latest CT development.