The team of developers at software pioneer CoreTechnologie have developed an inexpensive and super-light bicycle made from 3D-printed aluminum components and standard carbon tubes. The development demonstrates how complex everyday objects can be produced quickly, easily, and cost-effectively using 3D printing technologies.
The fully functional singlespeed version of the bike weighs just 7.1 kg ready to ride. In contrast to the conventional production of carbon frames, the simple workflow enables fast, uncomplicated, and automated production.
Optimal Frame Geometry
The CoreTechnologie software developers combined self-constructed, 3D-printed connecting parts made of aluminum (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 completed in a record time of just two months from idea to ready-to-ride prototype. The CT team optimized the design based on an existing 56 cm frame geometry and perfected it in numerous 3D renderings. By cleverly designing the frame parts, the single-speed 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 — which allows for 3D models from all common CAD formats to be read and prepared for additive manufacturing processes — to optimize wall thicknesses, generate surface textures, and realize the smooth production of 3D printed parts on the SLM machine of service partner FKM.
In numerous test rides, the 3D-printed bike proved that it is very robust and resilient and can be easily moved along different paths. With the project and the resulting prototype, the team from CoreTechnologie has shown that with the help of current software and hardware, the production of complex daily 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,” said Armin Brüning, CEO of CoreTechnologie.