Additive manufacturing has established itself in many areas of industry. Now, a collaboration between URWAHN, TRUMPF and H+E Produktentwicklung shows how 3D printing is also changing bicycle construction. The team developed a new generation of SOFTRIDE steel frames that are both lighter and stronger by using Laser Powder Bed Fusion (LPBF).
LPBF technology is based on the selective melting of metal powder using high-power lasers. This process enables a higher material density and precision than conventional manufacturing methods. One particular advantage is the freedom of design. The layer-by-layer production allows complex geometries with internal cavities to be realized. This reduces the weight and improves the mechanical properties of the frame.
The new production technology not only ensures a weight reduction of up to 30%, but also optimizes the production processes. TRUMPF provided the printing systems and material parameters, while H+E adapted the processes for series production. URWAHN integrated the findings into the frame design and adapted the geometry accordingly.
Another advantage of LPBF technology is the precise control of the layer structures, which means that strength and elasticity can be specifically influenced. High-alloy steels and optimized alloys ensure high stability with low material usage. In addition, complex post-processing steps such as welding are no longer necessary, which makes the production process more efficient.
The result is a frame that combines the lightness of aluminum with the aesthetics of a carbon monocoque. The frame geometry has been improved through topology optimization to ensure ideal load distribution. Three frame sizes for the Urban and Gravel segments are designed to offer both comfort and performance.
The entire development process – from the first sketch to series production – took less than eight months. The frame is produced on TRUMPF’s TruPrint 2000 at H+E Produktentwicklung in Moritzburg.
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