3d printed carbon fiber bike

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3d printed carbon fiber bike

Superstrata unveils ‘world’s first’ 3D-printed unibody electric bike

At that point you probably looked at everything that you needed to do to make a bike. Next, you need to consider the tools that are specific to typical framebuilding. Next, the materials for the bicycle frame itself. The process that I came up with takes advantage of the growing availability and affordability of CAD and 3D printing to allow people to build themselves a unique custom bicycle with unparalleled design flexibility. In addition to eliminating the jig, this method of construction has some major benefits.

Since the design is generated in CAD, it lets you create whatever geometry you want, rather than using standard preset angles that brazed lug construction requires. Whether you want road, mountain, track, even cargo or recumbent geometry, the freedom is there. My goal was to shift away from being restricted by the materials required by the tools, and instead enable you to realize your personal creative vision for what you want your bike to be. Disclaimer: While I'm not a composites engineer or a framebuilder, I'm an industrial designer working in the aerospace industry who has prototyped carbon fiber aircraft parts and has read an awful lot of composite manufacturing theory.

Still, when following these instructions and building your frame, think critically and safely and design conservatively. Having access to a friend or local makerspace with a desktop 3D printer will save a lot of money over using commercial 3D printing services, especially since neither the finish quality nor structural integrity of the printed parts are critically important to the build.

The first step in designing your bike is deciding what you want it to be. Fast and twitchy, stable and aerodynamic, sturdy and versatile, upright and relaxed? These traits and the riding position determine the tube angles and the kinds of components that you want your bike to accommodate.

Tube angles and fork geometry 2. Wheel size 3. Dropout spacing e. For my frame, I decided to use T6 aluminum tubing. It is lightweight, corrosion resistant, readily available and inexpensive, and well-proven in the cycling industry.

My choice of tubing diameters and wall thicknesses was based largely on precedent from other bicycles, and the commodity tubing that was available I bought mine from Aircraft Spruce.

This Is the World’s First 3D-Printed Carbon Bike

My main tubes are 1. Make sure that you do your research! My bicycle is going to be used for city riding by a lb rider. These wall thicknesses are not appropriate for mountain biking or heavier riders. Obviously, using different materials requires totally different tubesets as well. Tubeset manufacturers like Colombus, Dedacciai, Henry James and Nova Cycle Frames are good resources to find out what wall thicknesses are appropriate for different materials, applications, and locations on your bike.

The carbon fiber I used was primarily 0. I also used a small amount of 12K carbon fiber tow. The fiberglass I used is extremely light. I also purchased this through Aircraft Spruce, but these materials are available through many online suppliers.

That said, you should always take precautions to minimize your exposure to the uncured epoxy. For ease of assembly, I used a stock head tube, bottom bracket shell, dropouts, and V-brake bosses rather than fabricating them myself. You can buy these parts individually, but I liberated mine read: chopped them off with an angle grinder from suitable broken donor bicycles at my local DIY bike repair space in Toronto, BikeSauce.

It has all the basic functionality you need for this process sketching, extruding, sweeping, filleting, splitting, and shelling. Draw 2D sketches that lay out all the tubes and other key dimensions such as dropout spacing 2. Create transition sketches as necessary for curve sections e. Large, gentle radii are your friend.Published on August 11th, by Kyle Field.

August 11th, by Kyle Field. Carbon fiber bikes are nothing new, but when the tech gets together with 3D printing, things get crazy. Crazy awesome, that is. A new northern California startup, Superstrata, is looking to disrupt the cycling world with a new line of made-to-measure 3D printed e-bikes.

Superstrata launched an Indiegogo campaign to fund the production ramp of its first e-bike, offering the promise of custom e-bikes to the masses. Because they are printed to the exact specifications of the buyer, they are almost instantly going to be one of the lightest electric bikes on the market for each person.

That saves weight and increases the strength right off the bat.

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The customization of the bike stretches beyond just the size of the frame, as Superstrata is even offering buyers the ability to customize the stiffness of the frame. Traditional carbon fiber bikes have been around for ages, but are extremely brittle because of the seams required by the manufacturing process.

Superstrata opens pre-orders on a pair of 3D-printed bicycles

In the campaign, Superstrata is offering two different versions: Terra aka Superstrata Ca traditional bicycle, and Ion aka Superstrata Ewhich sports an electric motor and batteries capable of supporting 55 miles of riding per charge.

Superstrata is building smarts into both, with integrated wiring and data in both options. Superstrata also has a range of customization options for buyers, such as carbon fiber rims, different handlebars for racing, street, gravel, or touring, and colorway customizations. In total, there are more thanpossible configurations for buyers to tune and tweak to their satisfaction.

Check out the campaign page to see all the details or to place an order. They are scheduled to start shipping in December Sign up for our free daily newsletter or weekly newsletter to never miss a story. Have a tip for CleanTechnica, want to advertise, or want to suggest a guest for our CleanTech Talk podcast? Contact us here. Kyle Field I'm a tech geek passionately in search of actionable ways to reduce the negative impact my life has on the planet, save money and reduce stress.

Live intentionally, make conscious decisions, love more, act responsibly, play. The more you know, the less you need. Advertise with CleanTechnica to get your company in front of millions of monthly readers.

Want to publish a press release on CleanTechnica? Click on Contact at the top of the page. Follow cleantechnica. Bicycles Published on August 11th, by Kyle Field 0. Image courtesy: Superstrata.

3d printed carbon fiber bike

Twitter LinkedIn Facebook. About the Author. This site uses cookies: Find out more. Okay, thanks.Modern carbon-fiber bikes, stiffer and stronger than their metal counterparts at literally fractions of the weight, are technological marvels. Now, one tech company aims to change all that with the innovation of 3D printing. While the sophisticated-looking city bike is only a prototype, Arevo said it wants to move quickly into manufacturing by partnering with existing bike companies.

Robotic production could reduce the chances for errors in construction that lead to frame failures. And, the company said, its technology makes carbon fabrication affordable enough that bike manufacturers could make cost-competitive frames in the US.

Traditional carbon-composite manufacturing is notoriously labor-intensive, requiring human assembly and expert precision. Some high-end frames can have as many as individual pieces of carbon fiber.

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Instead of laying down plies of fabric in a mold, a printer head mounted on a robotic arm lays down carbon-fiber filaments, swiveling to orient them into a full bike frame. The resin is different, too. To Miller, manufacturing is only half the story. Prototyping could become far quicker, for one. Miller said Arevo can work with almost any commercially available carbon fiber, as well as blends like carbon-Kevlar.

He also pointed out that thermoplastics have much better toughness and durability than thermoset carbon composites, which are more brittle and susceptible to cracking. And robotic production should dramatically reduce the variability that occurs for handmade carbon. The bike industry has tried thermoplastics before, but certain drawbacks have prevented it from becoming widely used, especially for frames.

Weight is one issue. It may be an application, but not right away. That presents a higher economic hurdle, since most utility bikes today are made of metal, not carbon.

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But if it can solve some of the performance questions, Miller thinks Arevo could be a player in performance bikes, too. Arevo has already attracted investment from well-known engineer and venture capitalist Vinod Khosla, as well as a prior round of funding from In-Q-Tel, an investment arm of the CIA. The tech is scalable and can be used for everything from car parts to airplane wings. The company does plan on pursuing other markets. So, for its first showcase product, why a bike?

For starters, a bike is a large, complex object, and therefore a good test subject for manufacturing capability.

The Superstrata: Custom 3D-printed carbon fiber e-bike

Bikes and Gear. United States. Type keyword s to search. Today's Top Stories. How to Ride Bike Rollers. The Arevo bike frame is made up of 2-millimeter carbon-fiber filaments, with each filament itself comprising 10, individual strands.

This content is created and maintained by a third party, and imported onto this page to help users provide their email addresses. You may be able to find more information about this and similar content at piano. Advertisement - Continue Reading Below.

More From News.Earlier this year, a company called FLX released a bike called a Babymaker nope, not joking that quickly became an internet sensation. Through a targeted social media marketing campaign, the Babymaker was suddenly everywhere, following people from Instagram to Facebook to YouTube and back again. Lots of people saw the bike, and lots of people bought it.

Perhaps the most notorious example is SpeedX. We covered that in a major feature article that shone a light on a catastrophic downfall that left hundreds of people out of pocket, thousands of bikes dumped in fields, and contributed to the collapse of the Chinese share-bike industry. All of which is a looooong but necessary preamble. Because, guess what folks? It has generously proportioned valves. Yes, I have questions about that chainline. It involves lasers and robots, which is futuristic as hell.

It removes human error from the production line. It allows things to be shaped in novel ways, like, say, a bike frame without a seat tube.

3d printed carbon fiber bike

Bastionin Melbourne, pairs 3D-printed lugs to filament-wound carbon fibre tubing in its also very expensive road bikes. Also in Melbourne, a major bicycle brand that may or may not rhyme with Shrek is developing 3D-printed titanium bike frames with the metal additive manufactured company, Titomic. Their ability to begin production may be affected by product development or financial challenges.

If the Superstrata delivers on what it promises, however, there appear to be some interesting possibilities at play. Superstrata has thus far announced two models.

There are renderings of both models, but real-world photos are a little scant. Of course, there are also abundant comparisons to the competition, which show Superstrata in the best possible light. Fortunately, because height can be a confusing concept to grasp, there is a helpfully marked and outstanding visual representation of what short and tall people look like.

It is the light I need in these dark times. However, when it gets to the nitty gritty about the spec, or what you might get if this thing ever reaches production, details are a bit more scant.

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Did you spot the completely different frame design with no seat stays and a seat tubeor the broken freewheel that keeps those pedals spinning or the geared bike, set up as a single-speed ? Hint: the chain goes through the derailleur. But, as Superstrata tells usthe frame weighs less than both an entire element and two bottles of water of unspecified volume, so there is that. One hundred and forty years ago when the first safety bicycle was invented, penny farthing riders probably snorted into their moustaches.

I get that, and I wish the fine people at Superstrata all the best. Our mission is to bring you the best content in the world that showcases the beauty of cycling in all its glory. We want to inspire people to love the sport as much as we do, and ultimately pull you away from the computer to get out for a ride.

So we can keep doing this to the best of our ability, please join our mission by becoming a member. From exclusive content to premium benefits, join us and experience all we have to offer. Or feel free to continue reading the article.

Subscribe to newsletter. Member Log In Join us Become a member. October 11, October 10, October 9, October 8, We use cookies and other tracking technologies to improve your browsing experience on our site, show personalized content and targeted ads, analyze site traffic, and understand where our audiences come from.

To learn more or opt-out, read our Cookie Policy. Arevo is not a well-known name in the cycling world. The Superstrata Terra is a lightweight analog that can be custom-built for a variety of riding styles. And the Superstrata Ion is a Class 1 e-bike with a rear-hub W motor, a Wh battery, and an estimated 60 miles of range. Superstrata says the use of thermoplastic materials makes it extremely impact-resistant yet remarkably lightweight. The frame weight of the Terra is 2.

But the absence of a downtube really places the Superstrata in a class of its own. Customers can send in their measurements, and Superstrata will 3D-print the bike down to the spokes. Each frame takes about 10 hours to create, and the company claims it can create up tounique combinations. Crowdfunding for product launches, especially complicated products like e-bikes, is a lot harder than it sounds. Crowdfunded gadgets are sometimes delayed for months or years, and in some cases, they never ship at all.

If the company decides to abandon the project, bike owners could be left in the lurch when it comes to maintenance and repair. The company is launching its preorder in July and will start delivering bikes later this year.

The frame looks almost identical to the Superstrata, which makes sense considering Stephens consulted on the Emery as well. If the Superstrata is successful, Vu expects the legacy bike manufacturers to eventually come calling, eventually setting Superstrata to become a major supplier to the industry and 3D-printing to become an accepted manufacturing process in the cycling world.

And if the big bike companies want us to make carbon fiber frames for them? Cookie banner We use cookies and other tracking technologies to improve your browsing experience on our site, show personalized content and targeted ads, analyze site traffic, and understand where our audiences come from.

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3d printed carbon fiber bike

Fortnite Game of Thrones Books. Comics Music. Filed under: Tech Transportation Rideables. By Andrew J. Hawkins andyjayhawk Jul 13,am EDT. Linkedin Reddit Pocket Flipboard Email. Image: Superstrata Arevo is not a well-known name in the cycling world.

Grid View. Next Up In Tech.In addition to looking quite slick, the unibody bike is 3D printed from a single piece of carbon fiber material.

There are two models being offered under the Superstrata brand. Neither are quite a reality yet. Image Credits: Superstrata.

The advantages of a 3D-printed bike should be pretty clear. In all, the bike builders take 18 different measurements to create the unibody frame. Superstrata told TechCrunch that this translates into more thanunique combinations. Once the bike is printed, a human delivers the final touches. Superstrata is not just some new bike startup. To achieve this expanded focus, Arevo is building a print farm with a bunch of its systems in Vietnam, said Vu.

Vu is betting that future customers will be hooked once they understand and can see for themselves how quickly Superstrata was created.

3d printed carbon fiber bike

The entire process from the drawing board to a production-ready prototype took about two months, Vu said. Much of that time was spent designing the printing processes that will allow for so much customization between each bike. Vu is also aiming for Superstrata to be a high-quality product that can stand on its own, and the company leaned heavily on bike experts and designers to create both products. One of the most interesting — and possibly even controversial — design decisions is the lack of a seat tube.

The whole point is we can do the entire thing carbon fiber and support massive amounts of weight. One important note is that as customized as these two bikes might be, this is not a closed system that will require the owner to stick with the handlebars and wheels. The bikes can use other wheels and components. Superstrata made this flexible because the company assumed most hardcore cyclists will strip it down to the body or fork anyway. There is one other temporary upside.

The price of both bikes have been reduced for early adopters through the crowdfunding campaign. The product is expected to start shipping in December.Micah Toll.

And even 3D-printed bikes. These are ultra-customized, 3D-printed at the exact size and geometry required for each rider. In addition to the Superstrata Ion electric bike, Superstrata is also launching an acoustic non-electric version known as the Superstrata Terra.

The innovative Superstrata bikes are made possible thanks to novel 3D printing technology developed by Arevo. My friends were always so careful with their expensive carbon bikes, afraid for it to tip over or get hit. But they can be fragile.

Riders can further customize the bikes by choosing from four different styles racing, street, gravel, or touringtwo wheel materials metal or carbon fiberand two colorways light or dark.

While the Superstrata Terra requires you to do all the work, the Superstrata Ion is an electric bike with a battery hidden in the downtube of the frame. The bike is pedal assist-only, and thus the base model comes with a 36V battery rated for Wh of capacity, though the company has confirmed that a larger Wh battery is coming soon.

Superstrata claims a maximum range of up to 35 miles 56 km in the lowest pedal assist mode on the entry-level battery; however, e-bike ranges are notoriously wide and affected by many variables.

From my own experience, on one of my best rides I was able to go around 25 miles on 90Wh of battery with my W pedal assist bike, though that was with a good amount of huffing and puffing on my side.

And the custom printed frame that is unique for each rider certainly sets Superstrata apart. Both are available for pre-order now via Indiegogo with shipping beginning in December While that price seems rather low for a carbon fiber electric bike, Sonny explained that the reduced labor helps keep prices down. Most other carbon fiber frames require expensive, highly specialized labor. And while we can debate the ethics of robots replacing human workers, the impact on pricing is pretty darn clear.

What do you think? Let us know in the comments below! FTC: We use income earning auto affiliate links. Subscribe to Electrek on YouTube for exclusive videos and subscribe to the podcast. Be sure to check out our homepage for all the latest news, and follow Electrek on TwitterFacebookand LinkedIn to stay in the loop. Guides ebikes. July As Superstrata CEO Sonny Vu explained in a call with Electrek : My friends were always so careful with their expensive carbon bikes, afraid for it to tip over or get hit.

The carbon-fiber handlebars have a built-in display and remote for controlling the e-bike. You can send him tips at Micah electrek. Micah Toll's favorite gear. Fast and fun and affordable electric scooter!


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