CoreTechnologie launches its first single-speed bike featuring 3D-printed aluminium components

The software developer CoreTechnologie (CT) has recently developed a novel bicycle using 3D-printed aluminium components and ordinary carbon tubing, resulting in a lightweight and cost-effective design. CT software developers coupled self-designed, 3D-printed aluminium (AlMgSi10) connection pieces with Carbonforce machine-made, incredibly light carbon tubes. The tubes were joined using high-strength two-component glue commonly used in aerospace.

“In addition to the casual design and the driving pleasure, the super-light bike from Core Technologie put an incredulous smile on the testers’ faces when they lifted it,” stated visionary and CT Managing Director Armin Brüning.

From idea to ready-to-drive prototype, the project was accomplished in two months. The CT team improved and developed the design in many 3D renderings based on the current 56-centimetre frame geometry. The ingenious structure of the frame sections of the single-speed variant allows it to be upgraded with a gear change.

Due to their great riding qualities, the degrees of freedom afforded by computer-aided design (CAD) in combination with the 3D SLS printing method resulted in an incredibly light and simple structure, marking a counter-trend to technically sophisticated and heavy e-bikes. The software business used its 4D_Additive software in the intriguing project to optimise wall thicknesses, produce surface textures, and ensure flawless manufacturing of the 3D printed products on the SLM machine from service partner FKM.

In many test rides, the 3D-printed bike proved to be durable and resilient and can be ridden on various routes. The CoreTechnologie team proved, via the project and the accompanying prototype, that complex everyday and consumer items may be produced economically, quickly, and conveniently without relying on fragile supply networks.