Metal 3D Printing for Cycling & Sports Industries

Why are more and more bike builders, makers and manufacturers utilising 3D printing? Freedom of design is a major component – additive manufacturing allows for complexity and innovation that would be difficult or even impossible to achieve using traditional manufacturing methods. Parts can be additionally lightweighted through design, yet still maintaining the high strength-to-weight ratio and other qualities as the same metals as machined from billet material.

Bicycles can be uniquely customised and “made to measure” with 3D printing – at the same time, the additive manufacturing process is adaptable to scale production “on demand” – whether that is 1 part, or 10 parts, 100 or more as needed. Design changes can be seamlessly integrated into production, then replicated with repeatability and consistency.

At RAM3D, we have printed more than 12,000+ bicycle parts in titanium and stainless steel for diverse builders and makers across the bike industry.

We have 10+ years of experience in the production of a wide range of parts (bottom brackets, brake levers, chain stays, cranks, drop outs, extensions, forks, handle bars, head tubes, lugs, mounts, seat posts, stems, yokes, etc...) for various cycling setups – mountain bikes (MTB & ATB), road bikes, gravel, touring, endurance, racing, commuters, cruisers, ebikes, and more.

Looking to make your dream build – or explore the possibilities of metal 3D printing for ramping up production & fabrication?

Talk to us early in your design process. Our expertise and commitment to quality can help you determine how metal additive manufacturing is best suited to your bespoke bike project.

CASE STUDY

Sturdy Cycles

RAM3D have been metal 3D printing titanium parts for bespoke bicycle company Sturdy Cycles who are based in Somerset in the UK since 2015.

Tom used to compete as a professional athlete in Triathlons in the UK and Europe and even competed as far afield as Australia. He did this whilst studying and has a background in Aeronautical Engineering and Sports Biomechanics. It was while he was studying Sport Biomechanics, he started to get interested in bikes and started to think more seriously about bike design whilst competing.

With his broad range of expertise working in bike shops and R & D, it was a natural progression to get involved in frame-building. With bikes, he feels he is in control of the whole process from start to finish; from creating the design, engineering, and fabricating them. In his own words: “There aren’t many products that you, as one person, can cover the whole life cycle of. Even with the addition of metal 3D printing, it is still quite technical and challenging.”

Tom embraces the use of additive manufacturing in his frame building and feels this innovative technology allows him to create designs and structures that couldn’t be manufactured any other way. He explains: “There is the purist element with titanium, it doesn’t need to be painted or finished and for a lot of people, and that has a big appeal.”

The amount of titanium 3D parts on his bikes has certainly increased. In the beginning we printed the junctions and now print his forks, handlebars, crank set, seat posts, dropouts, bottom bracket, etc (there are 17 pieces per bike that we print for Tom). The forks took an incredible amount of work and have changed so much since the early ones were printed.

According to Tom, we now have a good production system that works for both of us. We have worked out a build system; we nest all the tall parts and the shorter parts together and it is working well. We are printing two builds per week.

RAM3D have been 3D printing parts for his five models, Fiadh (road bike), Sidhe (aero focus road bike), Éimear (race focus Time Trial model), Cilla (all road / adventure bike), and Tara (mountain bike) and involve Tom in the print process, advising on any improvements on designs to get the best outcome for his bespoke bikes.

Tom has learnt so much over the years from pushing the boundaries of metal 3D printing, from having to do reprints and change designs, but that is all part of the learning process. A combination of reprint, dimensional accuracy, and the strength of the part when it is in use in the final product.

OTHER PROJECTS

We have 3D printed innovative handlebars for Cycling New Zealand High Performance Programme for track cycling in the Olympics & Commonwealth Games. For other endurance athletes, we have manufactured handlebar extensions, and a custom aerobar for the NZ Ironman and Triathlon NZ.

Quote from Tom Sturdy, Managing Director, Sturdy Cycles

“RAM3D have been extremely easy to work with. Their communication is excellent, and parts are always delivered to schedule. The quality of the work that they produce is consistently high and I would recommend their services.”