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Customize your own bike with high-performance wire
In a recent breakthrough, the renowned wire manufacturer colorFabb has launched a high-performance 3D printed material called XT-CF20, a carbon fiber composite based on copolyester. This innovative wire is said to contain over 20% carbon fiber, offering exceptional rigidity, dimensional stability, and heat resistance. The introduction of this material marks a significant step forward in the world of 3D printing, especially for applications requiring strength and durability.
To showcase the potential of this new material, the colorFabb team took an ambitious approach by using a standard desktop 3D printer and XT-CF20 filament to create a fully functional bicycle. While the frame, wheels, and transmission system were 3D printed, some components were still manufactured traditionally. The goal was to prove that even with everyday 3D printing technology, it's possible to build something practical and robust.
The entire bike was designed using SOLIDWORKS software and then printed using an Ultimaker Original Plus. Once assembled, an intern from the design team, Stephen Schürmann, tested the bike by riding it through the town. The results were impressive—showing that 3D printed materials can be used for real-world, functional products.
"This project demonstrates that a racing bike can now be built using a common 3D printer and advanced composite materials," the colorFabb team explained. "Our aim was to create a real, usable bicycle that could be ridden under normal conditions. We want to inspire engineers and show them what modern 3D printing technology is capable of."
The XT-CF20 filament was chosen for its excellent stiffness-to-elongation ratio, making it ideal for structural parts. The bike’s weight met the standards required for competitive cycling, and its frame proved to be extremely strong. The team focused on printing load-bearing components, rather than the entire bike, using connectors and tubing for other parts due to time constraints.
For those interested in trying this themselves, colorFabb recommends using alternative materials like carbon fiber, titanium, aluminum, or bamboo for different parts. Most popular 3D printers, such as MakerBot and Ultimaker, are compatible with the necessary designs. The team also conducted finite element analysis to ensure the bike’s structural integrity and confirmed its usability through real-world testing.
"This is a new era in manufacturing," said Schürmann. "Soon, anyone can 3D print their own bicycle frame at home. With just basic SOLIDWORKS skills, you can create a custom bike tailored to your body and riding style. The learning curve is manageable, and there are many freely available design files online that you can use as a starting point."