Graduate Project
3D Printed Metal Bike Frame
A bike frame design optimized for additive manufacturing processes
Class
Design for Additive Manufacturing
Completion Date
Key Skills
SolidWorks · Product Design · Additive Manufacturing
Project Summary
Explored additive manufacturing for bicycle frame production.
Compared traditional carbon fiber and AM manufacturing methods.
Designed a frame optimized for metal 3D printing.
Goals/Requirements
Reduce manufacturing complexity and assembly time.
Minimize post-processing and secondary operations.
Improve design flexibility for custom frame geometries.
Evaluate the feasibility of additive manufacturing for bike frames.
Outcome
Use 45° diamond-shaped tubing to eliminate supports.
Reduce the design to three primary printed components.
Orient precision holes vertically for improved accuracy.
Prevent trapped powder and allow adjustable infill.
Simplified assembly by minimizing part count.
Eliminated precision welding through integrated components.
Enabled rapid prototyping and frame customization.
Optimized the design for additive manufacturing
Conclusion
Demonstrated the benefits of AM for bike frame design.
Highlighted customization and simplified manufacturing.
Identified print size and speed as current limitations.
Gallery