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3D Printing Progress
Posted on April 15, 2019 by  & 

World's first 3D-printed carbon fibre unibody bike frames

AREVO has announced a partnership with boutique bike manufacturer Franco Bicycles to deliver the world's first 3D printed, continuous carbon fibre single-piece unibody frame for a new line of eBikes Franco will sell under the "Emery" brand. For more information see the IDTechEx report on 3D Printing 2019-2029.
 
AREVO DNA™ technology is unique in the additive manufacturing (AM) world as it features patented software algorithms enabling generative design techniques, free-motion robotics for "True 3D" construction, and direct energy deposition for virtually void free construction all optimised for anisotropic composite materials.
 
The unibody bike frame construction uniquely enabled by AREVO technology is made as a single part, in contrast to current composite frames, which are made of many parts glued together. With AREVO's intelligent continuous carbon fibre placement, unprecedented structural integrity and stability are achieved. Finally, the AREVO DNA AM process takes the design and final manufacture of a bike frame from 18 months to just a few days at a significant reduction in product development costs.
 
The frames are in production now at AREVO's new multi-purpose facility in Milpitas and this achievement with the Emery One represents several breakthroughs for bicycle manufacturers, with implications for other industries as well. These breakthroughs include:
  • True serial, volume production of AM-made composite parts that are made with thermoplastic materials, which are tougher, durable and recyclable, as compared to brittle and non-recyclable thermoset materials
  • A replacement of a laborious manual process with a fully-automated, "lights out" production model
  • Delivering on the promise of localized manufacturing or "on-shoring," which creates greater independence for bike brands
  • A much greater "freedom of design" for bike manufacturers that creates the possibility of fully-customized bikes made on an "on demand" basis, an approach AREVO calls "DESIGN. PRINT. GO.™"
 
 
"We chose AREVO technology because its iterative and flexible design represents the new age in composites manufacturing, and we wanted to be the first bike company to help lead this revolution," said Hector Rodriguez, Co-Founder of Emery Bikes. "AREVO's continuous carbon fibre technology has been instrumental in achieving the ride quality and high-performance requirements we set out to accomplish with the Emery One."
 
"This is the first Composite Additive-Manufactured bike frame and it represents an important milestone for the AM industry as AREVO is delivering on the promise of on-demand manufacturing of composite parts in volume now," said Hemant Bheda, AREVO Co-Founder and Chairman. "With the introduction of the Emery One, the transformation of the global composite bike industry has begun."
 
source and top image: AREVO
Learn more at the next leading event on the topic: 3D Printing Europe 2020 External Link on 13 - 14 May 2020 at Estrel Convention Center, Berlin, Germany hosted by IDTechEx.
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