Recently, three British design companies have teamed up to create a titanium alloy 3D printed bicycle frame weighing less than 1kg. 3D printing company Mirada Pro, bicycle tube specialist Reynolds Technology, and frame manufacturer Ted James all contributed their knowledge of the frame and reduced their weight using topology optimization software.
Do you think that the additive manufacturing of sports is starting to make you bored? It won't happen now, as three British design pioneers are preparing to launch a most forward-thinking bicycle component in recent years: a 3D printed titanium frame that weighs only 999g. The expert in the production of the frame is Mirada Pro, a Birmingham metal 3D printing specialist who is currently focusing on the bicycle industry; Reynolds Technology, also from Birmingham's steel pipe business, has been serving bicycle enthusiasts for more than 120 years; Ted James, from Manufacturer of bicycle and BMX frames in Stroud, Lochester. Together, they combine their areas of expertise to create a topology-optimized frame that accelerates the use of 3D printing in bicycles.
From design to manufacturing in just eight weeks, this 3D printed frame is impressive. It is understood that although these British designers have not completely modified the wheels, their cooperation has the hope to make the most important contribution to the ever-expanding additive manufacturing bicycle stage. The frame features a custom titanium alloy 3 / 2.5 tube from Reynolds and a 3D printing sleeve connector designed by Mirada Pro to connect the head tube, bottom bracket, lower tube and top/sit tube. The metal parts were soldered by James, and a new frame with a torsional stiffness superior to that of a conventional alloy frame was born.
The use of topology optimization software is an important factor in the weight of the frame below 1kg. By entering the required load data, Mirada Pro is able to set up CAD software to make frame parts with less material, allowing the production of products of sufficient strength to be produced with a minimum of 6 / 4 titanium alloy 3D printed powder. This reduction in material usage not only makes the frame lighter, but also saves the design company's money, which means that a molded 3D printing frame can be incorporated into the future.
“The shape is controlled by one of our computer programs,†Iain McEwan, product engineer at Mirada Pro, told Cyclist. “We put the standard load that the frame needs to withstand the safety test, enter it into the program, and tell it to generate a shape that can support these loads and use the least amount of material. In other words, if you have a piece of titanium for the head tube Alloy, you can leave the material that can support the required load while removing other parts."
The 3D print frame has not yet become a complete bike, but it has been sent to a separate test lab where it will complete the subsequent test steps. If the results indicate that the frame is suitable for cycling, the three designers may one day create a 3D printing frame suitable for mass production.
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