CoreTechnologie 3-D prints super-light single-speed bike

The first 3-D printed single-speed bike. Photo: CoreTechnologie GmbH

Global software manufacturer CoreTechnologie (CT) has for the first time developed a particularly lightweight and inexpensive bicycle made from 3-D printed aluminum components and standard carbon tubes. The fully functional single-speed version of the bike weighs just 7.1kg and is ready to ride. In contrast to the conventional production of carbon frames, the simple workflow enables fast, uncomplicated, and automated production.

The CT software developers combined self-constructed, 3-D printed connecting parts made of aluminium (AlMgSi10) and machine-made, extremely light carbon tubes from the company Carbonforce which were joined using high-strength two-component adhesive utilised by 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 optimised the design based on an existing 56cm frame geometry and perfected it in numerous 3-D renderings. By cleverly designing the frame parts, the single-speed version can also be upgraded with gears.

As a result of the degrees of freedom made possible by computer-aided design (CAD) in conjunction with the 3-D SLS printing process, a particularly light and simple design was achieved that, due 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 4-D additive software to optimise wall thicknesses, generate surface textures, and realise the smooth production of 3-D printed parts on the SLM machine of service partner FKM.

In numerous test rides, the 3-D 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.