3D printing rolls into the bicycle industry

Friedrichshafen, Germany — 3D printing for bicycles frames and seats is on full display at the Eurobike trade show in Friedrichshafen, Sept. 4-7.

Silicon Valley technology company Arevo DNA will produce 3D-printed carbon fiber unibody frames for the new line of e-bikes from Dutch designer and producer of bicycles Pilot Distribution Group BV.

The new bike, called EVE9, is on display at Eurobike, billed as the world's largest cycling show.

"Arevo's continuous carbon fiber technology is very impressive as it affords numerous design possibilities and provides excellent strength and durability," said Arno Pieterse from Pilot, describing the technology as "truly a revolution in composites manufacturing."

The new deal marks Arevo's second major customer win in the cycling industry within the last six months.

In April, the company announced a deal with boutique bike manufacturer Franco Bicycles to deliver continuous carbon fiber, single-piece unibody frames for the company's Emery brand of e-bikes.

According to Arevo, Emery frames, which are of a different design, are already in volume production at Arevo's headquarters manufacturing center in Milpitas, Calif.

Arevo claims that its patented software algorithms enable generative design techniques and free-motion robotics for "True 3D" construction.

In addition, the company said, the algorithms allow for "direct energy deposition for virtually void-free construction all optimized for anisotropic composite materials."

Turning to bicycle seats, bike parts supplier Fizik announced at Eurobike a partnership with Carbon Inc. of Redwood City, Calif., to digitally print the padding for its Adaptive saddle.

Carbon's Digital Light Synthesis (DLS) technology uses digital ultraviolet light projection, oxygen-permeable optics and programmable liquid resins to produce parts that have high-quality mechanical properties, resolution and surface finish.

The DLS technology allows Fizik's designers, sports scientists and engineers to precisely address cyclists' needs for power transfer, shock absorption, stability and comfort — without the constraints of traditional foam. The company used pressure mapping data collected over nine years from the world's best professional cyclists to produce the new Adaptive saddles, which have a lattice geometry.

And in the future, Carbon's DLS technology could allow Fizik one day to scan a customer's pressure mapping in bike shops and use it to build fully personalized saddles.

"Our aim is to provide riders with bespoke performance products tailored to their individual biodynamic data," said Luca Mathia Bertoncello, Fizik brand director. Fizik is owned by Italian bicycle seat specialist Selle Royale SpA.

Plastics News Europe contributed to this report.